Removing Mold By Destruction Patents (Class 264/317)
  • Patent number: 5580507
    Abstract: A method of making a mold from a model is disclosed. A mold carrier is formed having an aperture therein. The aperture has a configuration generally corresponding to the shape of the model. The model is positioned within the aperture such that a space is created between the outer peripheral surface of the aperture and the outer peripheral surface of the model. A resilient first material in its liquid state is poured into the space such that the first material substantially covers the outer peripheral surface of the model. The resilient first material is allowed to solidify in the space such that a resilient mold insert is formed. The mold insert forms an impression of the outer peripheral surface of the model and is disposed along the inner peripheral surface of the aperture. The model is removed from the resilient mold insert. A second material in its liquid state is poured into the aperture of the mold carrier with the resilient mold insert disposed along the inner peripheral surface of the aperture.
    Type: Grant
    Filed: April 13, 1995
    Date of Patent: December 3, 1996
    Assignee: Nike, Inc.
    Inventors: Daniel A. Williamson, Steven R. Castellanos, Bruce J. Kilgore, John C. Tawney
  • Patent number: 5560883
    Abstract: A method is provided for forming a synthetic corrosion product layer on tube surfaces. The method utilizes two dissimilar materials with different coefficients of thermal expansion. An object tube and sacrificial tube are positioned one inside the other such that an annular region is created between the two tubes' surfaces. A slurry of synthetic corrosion products is injected into this annular region and the assembly is heat treated. This heat causes the tubes to expand, the inner tube with the higher coefficient of expansion expanding more than the outer tube, thereby creating internal pressures which consolidate the corrosion products and adhere the corrosion products to the tubing surfaces. The sacrificial tube may then be removed by conventional chemical etching or mechanical methods.
    Type: Grant
    Filed: June 7, 1995
    Date of Patent: October 1, 1996
    Assignee: The United States of America as represented by the United States Department of Energy
    Inventors: Michael H. Lane, Eugene J. M. Salamon
  • Patent number: 5547714
    Abstract: A process forms an amorphous carbon film over a solid, which film has physical and chemical properties similar to those of diamond. Its ancillary objects are the solid bodies so coated and the self-sustained film obtained in a subsequent stage of dissolution of said substrate. The process includes generating a highly accelerated beam of carbon-hydrogenated ions, which beam is made to impact with sufficiently high energy on the surface of the substrate. The beam is concentrated by electrostatic lenses and homogenized by a magnetic mass separator. The process forms on a solid substrate, a film with properties similar to those of diamond, such as high hardness, high chemical stability, transparency, high heat conductivity and high electric resistivity; obtainable at ambient temperature, and which is simpler than known procedures.
    Type: Grant
    Filed: April 12, 1995
    Date of Patent: August 20, 1996
    Assignee: Comision Nacional de Energia Atomica
    Inventors: Hugo A. Huck, Alberto E. Jech, Ra ul Righini
  • Patent number: 5543108
    Abstract: A method of making microstructure bodies of plastic material. A microstructured plate-like base body which is made by any known molding procedure and which has a first side serving as a first reference plane and a second side which has plastic microstructures projecting therefrom is covered at its second side with a material layer that engages the microstructures, whereupon the material layer is machined to provide a second reference surface parallel to the first reference surface and the base body is then machined parallel to the second reference surface to expose the microstructures projecting therefrom and the material layer is finally removed selectively with respect to the plastic material to release the microstructured bodies.
    Type: Grant
    Filed: June 9, 1994
    Date of Patent: August 6, 1996
    Assignees: Forschungzentrym Karlsruhe GmbH, B urkert GmbH
    Inventors: Walter Bacher, Hans Biedermann, Heinz Dinglreiter, Helmut Kalb
  • Patent number: 5538677
    Abstract: An elastic layer is formed stably of constant shape without cutting of surface thereof and without difficult processing to make an internal surface of hollow in a mold into an off-right-circular cylinder shape. A matrix 1 is produced by shaping a periphery of rod material into an inverted crown shape of off-right-circular cylinder. Annular reinforcements 2, 3 are fixed on the both ends of inverted crown portion of matrix 1. The matrix 1 with the reinforcements 2, 3 is dipped in an electrolytic solution 5a, so that a nickel alloy is deposited over a surface of matrix 1 by electroforming to obtain a mold 4. The mold 4 is cut outside the reinforcements 2, 3 and a hollow for dissolution removal is perforated along the axis of matrix 1. The mold 4 is dipped in a corrosive solution which can dissolve only the matrix 1, so that only the matrix 1 is dissolved to remove away from the mold 4. The remaining mold 4 will have a hollow of inverted crown therein.
    Type: Grant
    Filed: February 9, 1995
    Date of Patent: July 23, 1996
    Assignee: Canon Kabushiki Kaisha
    Inventor: Masaaki Takahashi
  • Patent number: 5529740
    Abstract: A process for treating a liquid crystal polymer film which includes the steps of: heating a film obtained by extrusion molding of a liquid crystal polymer, while contacting at least one surface of the film with a supporting body, to melt the polymer; cooling the melted polymer to form a solidified polymer layer; and separating the solidified polymer layer from the supporting body. The process readily provides liquid crystal polymer films having excellent resistance to intra-layer delamination and high tensile strength and elongation, as well as excellent resistance to abrasion, dimensional stability when heated, and resistance to folding.
    Type: Grant
    Filed: September 16, 1994
    Date of Patent: June 25, 1996
    Inventors: Randy D. Jester, John A. Penoyer, Douglas D. Roth, Detlef Frank, Minoru Onodera, Takeichi Tsudaka, Toshiaki Sato, Tohei Moritani
  • Patent number: 5527559
    Abstract: A method of making a diamond film on a graphite substrate is disclosed, which comprises the steps of forming a layer of carbon-containing compound on a surface of the graphite substrate and controlling said compound to be rich or lean in carbon with respect to the stoichiometric carbon content in the compound to adjust the adherence of a diamond layer to be deposited on said layer of carbon-containing compound; and depositing a synthetic diamond layer on said layer of carbon-containing compound.
    Type: Grant
    Filed: July 18, 1994
    Date of Patent: June 18, 1996
    Assignee: Saint Gobain/Norton Industrial Ceramics Corp.
    Inventor: Matthew Simpson
  • Patent number: 5520871
    Abstract: A method of manufacturing a spherical pigging device for passing through a pipeline by forming a water soluble spherical core, affixing numerous magnets to the surface of the core, suspending the core within a spherical mold, pouring a liquid between the mold and the core that will cure to form a spherical body, removing the spherical body and dissolving the core to leave a hollow spherical body with the magnets encased within it.
    Type: Grant
    Filed: August 18, 1995
    Date of Patent: May 28, 1996
    Assignee: TDW Delaware, Inc.
    Inventors: Jeffrey Rosenberg, Steve Worthen
  • Patent number: 5518674
    Abstract: A method of forming an interconnect including the steps of providing a processing substrate, adhering a first electrically insulating layer to the substrate, forming an electrically conductive pattern on the first electrically insulating layer, forming a second electrically insulating layer adhered to the first electrically insulating layer with the electrically conductive pattern between the first and second electrically insulating layers, forming connections to the pattern and then removing the adhered first and second electrically insulating layers and the electrically conductive pattern from the substrate to provide a freestanding film.
    Type: Grant
    Filed: September 25, 1992
    Date of Patent: May 21, 1996
    Assignee: Texas Instruments Incorporated
    Inventors: Donald A. Powell, Susan V. Bagen
  • Patent number: 5516477
    Abstract: A molded article is prepared by forming a glass core, treating the glass core to induce residual stresses therein, inserting the core into a mold, injecting resin into the mold, curing the resin, fracturing the core to produce glass particles, and removing the glass particles from the molded article.
    Type: Grant
    Filed: August 1, 1994
    Date of Patent: May 14, 1996
    Assignee: Ford Motor Company
    Inventors: Carl F. Johnson, Brenda M. Vyletel
  • Patent number: 5511762
    Abstract: A method of manufacturing an open top, walled member for containing a molten metal, including the steps of forming an inner wall of a mold with a metal sheet and an inner lining covering the sheet, wherein the inner wall defines an inside surface of the walled member and transferring a casting compound between an outer wall of the mold and the inner lining of the inner wall to form the walled member. The metal sheet and inner lining are then removed to allow one to apply heat to dry the casting compound. In the case where the metal sheet includes a plurality of openings, one may also retain the inner wall during the heating step. The heat to dry the casting compound is applied to the inner lining to a sufficient temperature to melt the inner lining and uncover said openings of the metal sheet. The metal sheet is removed when the casting compound is dried.
    Type: Grant
    Filed: November 22, 1993
    Date of Patent: April 30, 1996
    Assignee: Magneco/Metrel, Inc.
    Inventors: Charles W. Connors, Jr., James S. Irwin
  • Patent number: 5510065
    Abstract: The injection molding of an elongated thin-walled tubular product such as a medical catheter is accomplished through the mounting of an elongated core pin on the interior of an elongated mold cavity wherein tension is continuously applied to the core pin for the purpose of maintaining it in a predetermined, substantially centered relation to the mold cavity and further maintaining a straight line configuration of the core pin along its length. The plastic material from which the product is formed is introduced into the mold cavity while at the same time overcoming any imbalance in the flow of the plastic melt into the mold cavity and as it travels in surrounding relation to the core pin and along its length by adjusting the position of the core pin relative to the inner surface of the mold cavity.
    Type: Grant
    Filed: March 20, 1989
    Date of Patent: April 23, 1996
    Inventor: Richard H. McFarlane
  • Patent number: 5505893
    Abstract: A method of manufacturing an open top, walled member for containing a molten metal, especially a flowing molten metal or reconstructing a worn or damaged member. The method includes the step of forming the inner walls of a mold which define the inner surfaces of the walled member of an open metal mesh screen which is meltable by the molten metal which is to be contained. The next step is to transfer, usually by pumping, an alumina-silicon carbide casting compound into the space between the open mesh metal screen and the outer walls defining the mold, which outer walls may be in situ structures. If an existing walled member is being repaired, any damaged or worn portions of the existing walled member are removed and the casting compound is poured in to replace these portions. The next step is to apply heat to dry the casting compound while the open mesh screen of the mold remains in place in contact with the casting compound.
    Type: Grant
    Filed: October 25, 1994
    Date of Patent: April 9, 1996
    Assignee: Magneco/Metrel, Inc.
    Inventor: Charles W. Connors, Jr.
  • Patent number: 5503785
    Abstract: Processes and apparatus are disclosed for producing three-dimensional objects having overhanging portions freely suspended in space without any material of the object in direct, supporting engagement therewith in the final geometry of the object. A support structure is formed by depositing material which will be under the ultimately suspended portions of the object to be formed, during a process in which material is built up in layers to form the object as well as the underlying support structure. A readily removable support structure is formed along an interface with the underside of the suspended portion of the object structure. A weak, removable or breakable joint is formed along that interface by the use of an interface material which forms a weak or dissolvable bond with the material of the object. The release material may be deposited as a separation layer, or as a thin coating.
    Type: Grant
    Filed: June 2, 1994
    Date of Patent: April 2, 1996
    Assignee: Stratasys, Inc.
    Inventors: S. Scott Crump, James W. Comb, William R. Priedeman, Jr., Robert L. Zinniel
  • Patent number: 5499980
    Abstract: A thin wall balloon for a balloon catheter is formed by depositing a film (such as polyimide) over a substrate which has an exterior surface configuration corresponding to a desired shape of the balloon in an inflated (or deflated) condition. After the polyimide film is cured, the substrate is removed from within the polyimide film by chemically dissolving the substrate.
    Type: Grant
    Filed: June 16, 1994
    Date of Patent: March 19, 1996
    Assignee: SciMed Life Systems, Inc.
    Inventor: Charles L. Euteneuer
  • Patent number: 5498377
    Abstract: A method for producing a thermoplastic polyurethane elastomer tube where the temperature of the mandrel and the extrusion pressure used for extruding a thermoplastic polyurethane elastomer are determined before preparing the tube. The temperature of the mandrel and the extrusion pressure are set to overlap two predetermined temperature ranges. One temperature range permits hot drawing of the tube preform, and the second temperature range provides a tube preform free from the occurrence of bubbles on its surface. After the two temperature and extrusion pressure ranges are determined, a thermoplastic polyurethane elastomer is extruded on the periphery of a heated mandrel under pressure using a mandrel temperature and extrusion pressure where the two predetermined ranges overlap. Thereafter, the mandrel is pulled out to provide a tube preform, and the tube preform is hot drawn to produce a tube having a desired outer diameter.
    Type: Grant
    Filed: November 21, 1994
    Date of Patent: March 12, 1996
    Assignee: Mitsubishi Cable Industries, Ltd.
    Inventors: Hidenori Ozaki, Minoru Fuchimoto, Tamotsu Kaide
  • Patent number: 5482248
    Abstract: A mold for forming an open top, walled member having side walls and a bottom surface for containing a molten metal. The mold including an inner screen having a plurality of openings having inner side walls and a bottom surface. The mold further includes an outer wall, wherein the inner screen and the outer wall are spaced relative to each other to define a space so that the side walls and the bottom surface of the open top, walled member are formed therebetween.
    Type: Grant
    Filed: November 15, 1993
    Date of Patent: January 9, 1996
    Assignee: Magneco/Metrel, Inc.
    Inventor: Charles W. Connors, Jr.
  • Patent number: 5470517
    Abstract: A method of pultrusion is provided that includes the steps of saturating a bundle of fibers in a curable resin, pulling the saturated fibers (also known as "prepreg") into a flexible mold, manipulating the mold (with the saturated fibers therein) into a given shape or form, allowing the saturated fibers to cure or harden, and then removing the flexible mold by mechanical or chemical means. This novel method permits one to mold prepreg into any given shape prior to hardening, not limited by the shape of a given mold or die.
    Type: Grant
    Filed: December 9, 1994
    Date of Patent: November 28, 1995
    Inventor: Ed Conley
  • Patent number: 5460760
    Abstract: According to the present invention, the copolymers of ethylene vinyl alcohol are extruded using extrusion equipment coated with a fluoropolymer. This method improves the processability, alleviates/slows down die buildup, improves the extrudate quality by reducing die lines on surfaces of the extruded product.
    Type: Grant
    Filed: April 18, 1994
    Date of Patent: October 24, 1995
    Assignee: Mobil Oil Corporation
    Inventors: Mingliang L. Tsai, Tien-Kuei Su
  • Patent number: 5447672
    Abstract: A method of manufacturing flexible thick-wall capillary tubing, comprising the steps of extruding a plastics sheath around a filament of uniform diameter, and withdrawing the filament from the sheath to form a length of tubing having a capillary bore which has been defined by the filament. The method enables the manufacture of fine-bore capillary tubing having a tightly controlled bore diameter.
    Type: Grant
    Filed: January 14, 1994
    Date of Patent: September 5, 1995
    Assignees: Alexander George Brian O'Neil, Christine O'Neil
    Inventor: Alexander G. B. O'Neil
  • Patent number: 5445772
    Abstract: A method of producing a patterned shaped article includes the steps of disposing at a prescribed position within a main form for molding the shaped article a projection-bristling form having a support member and a plurality of projections standing upright from the support member, charging a prescribed amount of dry pattern-course material for forming the pattern course of the shaped article into spaces defined by a prescribed number of projections of the bristling form, charging a base-course material for forming the base course of the shaped article into the main form including the remaining space of the bristling form not filled with the pattern-course material, removing the bristling form, causing the charged pattern-course material and base-course material to set into a shaped article, removing the shaped article from the main form and, optionally, sintering the shaped article.
    Type: Grant
    Filed: May 22, 1992
    Date of Patent: August 29, 1995
    Assignee: CCA Inc.
    Inventors: Hiroshi Uchida, Mituhiro Onuki, Hideo Watanabe
  • Patent number: 5441690
    Abstract: The present invention relates to an improved pinless connector for use in microelectronics comprising an improved elastomer resin of polysiloxane and filler.
    Type: Grant
    Filed: July 6, 1993
    Date of Patent: August 15, 1995
    Assignee: International Business Machines Corporation
    Inventors: Juan Ayala-Esquilin, Brian S. Beaman, Rudolf A. Haring, James L. Hedrick, Da-Yuan Shih, George F. Walker
  • Patent number: 5435960
    Abstract: A core ring assembly for use in production of a plastic injection-molded component is formed by injecting molten metal alloy into core dies to produce two intricately shaped ring type elements--one male, one female. Removing the male and female ring elements from the core dies and combining the two elements in an assembly machine to form a uniform, geometrically symmetrical, integral core ring assembly. The core ring assembly is transported to a plastic molding machine for overmolding the core ring assembly with either thermosetting or thermoplastic material. Then, the core assembly is melted out from the plastic component in a hot oil bath or induction melt-out, and the molten alloy recovered thereby is returned to a molten metal alloy tank for reuse.
    Type: Grant
    Filed: January 14, 1994
    Date of Patent: July 25, 1995
    Assignee: Freudenberg-NOK General Partnership
    Inventors: Ulrich Bressler, Michael Brummer
  • Patent number: 5431870
    Abstract: For producing connections made from composite material for structures having at least two hollow or non-hollow bars, interconnected by at least one hollow connecting joint, separate production takes place of blanks of said different parts with the definitive shapes, but in which the impregnation resin for the assembly of said blanks has not yet been introduced, after which they are assembled by thermosetting resin transfer moulding, so as to produce the resin matrix of the connecting joint or the complete structure at the same time as the assembly. The blanks of the connecting joints are obtained by compressing a planar textile complex formed from hot preformable textile fibers between a cavity of a shaping mould and a countermould, by cutting and folding down onto the countermould the overlap parts and performing a thermal preforming cycle.
    Type: Grant
    Filed: December 2, 1993
    Date of Patent: July 11, 1995
    Assignee: Eurocopter France
    Inventor: Gautier Andre
  • Patent number: 5415373
    Abstract: A melt core constructed of a low temperature melting point alloy for producing a cavity in a structural part manufactured by injection molding, the melt core being formed as a hollow body. Depending upon the production process employed, the hollow body is provided with an opening, which is tightly sealed by a separately produced cover constructed of the same material as the hollow body that it seals.
    Type: Grant
    Filed: May 20, 1994
    Date of Patent: May 16, 1995
    Assignee: Firma Carl Freudenberg
    Inventor: Michael Brummer
  • Patent number: 5389314
    Abstract: An inflatable medical device for the delivery of medications to an organ in the body including a catheter having a plurality of lumens (13, 22, 28) disposed therein. The distal end of the catheter is adapted to be disposed within a bodily organ. A hollow, inflatable, medication-deliverable balloon (16) is disposed on the distal end of the catheter and the interior of the balloon (16) is in fluid flow relationship with one of the lumens (22) to enable the balloon (16) to be inflated. An array of conduits (40) is disposed within the walls of the balloon for the delivery of medications to predetermined locations within said bodily organ. Another lumen (28) in the catheter shaft (14) is provided to deliver medications to the conduits (40) in the wall of the balloon (16). An egress (17) for the medications is provided so that they may be dispensed at the site being treated.
    Type: Grant
    Filed: July 7, 1993
    Date of Patent: February 14, 1995
    Assignee: Boston Scientific Corp.
    Inventor: James C. Wang
  • Patent number: 5385700
    Abstract: The invention involves a method of making a holder of solid ceramic material by locating a core in a mass of particulate ceramic material, consolidating the particulate material around the core, removing the core from the particulate material to leave a green artifact having a cavity, and sintering the green artifact. The core is shaped and the particulate material is arranged such that the core is in the form of a thin slab between a pair of layers of the particulate material. After sintering, the cavity comprises a thin gap between opposed plates of sintered ceramic material. The slab has openings therethrough which are filled with the particulate material, which, after sintering, forms a bridge across the gap, between the associated plates and sintered thereto.
    Type: Grant
    Filed: April 29, 1992
    Date of Patent: January 31, 1995
    Assignee: Programme 3 Patent Holdings
    Inventor: Ivor E. Denton
  • Patent number: 5376321
    Abstract: A method of producing a patterned shaped article includes the steps of constituting a patterning form by disposing at a prescribed position within a main form for molding the shaped article an auxiliary form of a configuration appropriate for a pattern to be formed, charging a dry material for pattern formation into the patterning form at a prescribed form cavity portion thereof, charging a base-course material for forming the base course of the shaped article into the remaining space of the patterning form not filled with the pattern material, removing the auxiliary form, causing the pattern material and base-course material charged into the patterning form to set into a shaped article, removing the shaped article from the main form and, optionally, sintering the shaped article.
    Type: Grant
    Filed: August 27, 1991
    Date of Patent: December 27, 1994
    Assignee: CCA Inc.
    Inventors: Hiroshi Uchida, Mituhiro Onuki, Hideo Watanabe
  • Patent number: 5374388
    Abstract: This invention includes an apparatus and method for molding and curing a curable composite patch used for repairing damaged contoured surface structures. The molding apparatus has a fluid impermeable outer container having a flexible outer wall. A flexible, fluid impermeable inner container containing a moldable granular material is positioned within the outer container and has a flexible molding wall on which the composite patch can be placed. Inner and outer ports are located on the inner and outer containers for evacuating the inner and outer containers. A model of an undamaged surface is formed by positioning the molding wall of the inner container against an unaffected surface and evacuating the inner container so that the granular material is rigidly held in a molded form. The patch is placed on the molding wall and the outer container is sealed with the outer wall positioned over the patch and molding of the inner container.
    Type: Grant
    Filed: April 22, 1993
    Date of Patent: December 20, 1994
    Assignee: Lockheed Corporation
    Inventor: James A. Frailey
  • Patent number: 5372768
    Abstract: A two-phase thermoplastic composition adapted for forming thermoplastic patterns. The composition comprises an organic thermoplastic pattern material and at least about 5% by weight of discrete particles of cross-linked poly(methylmethacrylate) that are physically stable at temperatures above 130.degree. F. Also disclosed are investment casting patterns of such composition and processes utilizing such composition.
    Type: Grant
    Filed: August 30, 1993
    Date of Patent: December 13, 1994
    Assignee: Yates Manufacturing Co.
    Inventor: Paul Solomon
  • Patent number: 5372178
    Abstract: This invention relates generally to a novel method of preparing self-supporting bodies, and novel products made thereby. In its more specific aspects, this invention relates to a method for producing self-supporting bodies comprising one or more boron-containing compounds (e.g., a boride or a boride and a carbide, etc.) by reactive infiltration of molten parent metal into a preform comprising boron carbide or a boron donor material combined with a carbon donor material and, optionally, one or more inert fillers, to form the body. Specifically, a boron carbide material or combination of a boron donor material and a carbon donor material, and in either case, optionally, one or more inert fillers, are sedimentation cast, spray coated, tapped, slip cast, pressed, etc., onto or into a body and into a particular desired shape.
    Type: Grant
    Filed: January 15, 1992
    Date of Patent: December 13, 1994
    Assignee: Lanxide Technology Company, LP
    Inventors: Terry D. Claar, Gerhard H. Schiroky, Donald P. Ripa, William B. Johnson
  • Patent number: 5368791
    Abstract: A method of producing a patterned shaped article includes the steps of disposing at a prescribed position within a main form for molding the shaped article a cell form having a plurality of cells arranged in a contiguous manner, charging a prescribed amount of dry pattern-course material for forming the pattern course of the shaped article into prescribed cells of the cell form, charging a base-course material for forming the base course of the shaped article into the remaining space of the main form not filled with the pattern-course material, removing the cell form, causing the charged pattern-course material and base-course material to set into a shaped article, removing the shaped article from the main form and, optionally, sintering the shaped article.
    Type: Grant
    Filed: September 30, 1991
    Date of Patent: November 29, 1994
    Assignee: CCA Inc.
    Inventors: Hiroshi Uchida, Mituhiro Onuki, Hideo Watanabe
  • Patent number: 5362429
    Abstract: A method for molding experimental, prototype and replacement parts from rubber-like materials using a frangible core wherein a core is made by coating a cavity with a mold release agent, coating the release agent with a quick set resin, pouring a two-part polyurethane resin into the cavity, sealing the cavity and allowing the polyurethane to foam, expand and adhere to the quick set resin.
    Type: Grant
    Filed: March 8, 1993
    Date of Patent: November 8, 1994
    Assignee: Magnum Manufacturing, Inc.
    Inventors: Dennis J. Orlewicz, William P. Orlewicz, Lawrence W. Orlewicz
  • Patent number: 5362712
    Abstract: In the process for producing molded bodies from precursors of oxidic high-temperature superconductors a copper mold of the desired shape which encloses a solidified bismuth strontium calcium cuprate melt is treated with a solution of a soluble compound containing sulfate anions, an aqueous mineral acid and an oxidizing agent until the copper mold is dissolved. A protective layer of at least one of strontium sulfate or calcium sulfate is formed on the solidified melt.
    Type: Grant
    Filed: June 23, 1993
    Date of Patent: November 8, 1994
    Assignee: Hoechst Aktiengesellschaft
    Inventors: Eberhard Preisler, Joachim Bock
  • Patent number: 5360050
    Abstract: A film-like molded body having a hollow portion of a predetermined contour and made from a disappearing material is formed first using a mold. Also, a disappearing model is prepared by dividing it into a plurality of disappearing model elements. Then, the disappearing model elements are placed so as to enclose the film-like molded body with the film-like molded body as a core and are bonded together and fixed using an adhesive. Accordingly, the disappearing model can be prepared easily while preventing the adhesive from being forced out into the disappearing model and dispensing with extraction of the film-like molded body.
    Type: Grant
    Filed: March 24, 1994
    Date of Patent: November 1, 1994
    Assignee: Asahi Tec Corporation
    Inventor: Hidenobu Miyajima
  • Patent number: 5354394
    Abstract: There is disclosed an apparatus and method for forming a honeycomb core. In particular, the apparatus comprises a compressible array of heater rods that are interleaved with layers of a formable material. Upon compressing the array, the formable material conforms to the shape of the heater rods. Through the application of heat and pressure, the different layers of the formable material are caused to bind to each other. The bound layers thereby form a honeycomb core, which is then removed from the forming apparatus. Also disclosed herein are methods of making honeycomb core using the apparatus, as well as methods of determining precise curing conditions for the making of honeycomb core, by sensing the temperature and pressure transmitted to the formable materials during the curing process.
    Type: Grant
    Filed: February 22, 1993
    Date of Patent: October 11, 1994
    Assignee: Seeton Technologies
    Inventors: H. Freeman Seebo, Robert E. Holeton
  • Patent number: 5348798
    Abstract: An improved method for forming a hollow core structural member, such as an automotive bumper beam, from moldable plastic sheets, such as fiberglass reinforced plastic sheets, by providing a press having a desired shape on the opposing members of the press, placing opposed sheets in the press with a layer of frozen, meltable material, such as ice, in place between them, forming the sheets into the desired article configuration in the press, removing the formed member from the press, then melting and removing the meltable material from the interior of the formed member.
    Type: Grant
    Filed: October 30, 1992
    Date of Patent: September 20, 1994
    Assignee: Azdel, Inc.
    Inventors: Albert H. Berghuis, Richard C. McKechnie, Albert Drenth
  • Patent number: 5348693
    Abstract: A method and system for making a three dimensional product wherein the size and shape of a plurality of cross-sectional segments of the three dimensional object are determined which when assembled together in a particular sequence form the desired three dimensional shape. Thin layers of material in the shape of each of the cross-sectional segments are applied in the particular sequence in which they form the three dimensional object. The application of each of the layers is much like a lithographic printing process in that a resin may be applied by a roller in the shape of the cross-sectional segments.
    Type: Grant
    Filed: November 12, 1991
    Date of Patent: September 20, 1994
    Assignee: Advanced Cardiovascular Systems, Inc.
    Inventors: Charles S. Taylor, William B. Tiffany, Paul Cherkas, John J. Frantzen, Hilary J. Hampton, Leonard Nanis, Bhupendra O. Shah
  • Patent number: 5334342
    Abstract: A high temperature resist process is combined with microlithographic patterning for the production of materials, such as diamond films, that require a high temperature deposition environment. For diamond films, a high temperature silicon nitride resist can be used for microlithographic patterning of a silicon substrate to provide a uniform distribution of diamond nucleation sites and to improve diamond film adhesion to the substrate. A fine-grained nucleation geometry, established at the nucleation sites, is maintained as the diamond film is deposited over the entire substrate after the silicon nitride resist is removed. The process can be extended to form surface relief features, such as "moth eye" surfaces, and microstructures of fine-grained polycrystalline diamond, such as rotatable microgears and surface relief patterns, that have the desirable characteristics of hardness, wear resistance, thermal conductivity, chemical inertness, anti-reflectance, and a low coefficient of friction.
    Type: Grant
    Filed: May 4, 1993
    Date of Patent: August 2, 1994
    Assignee: Rockwell International Corporation
    Inventors: Alan B. Harker, Jeffrey F. DeNatale, Patrick J. Hood, John F. Flintoff
  • Patent number: 5330694
    Abstract: A method of patterning a concrete surface and a pattern transfer mat for use in the method. The pattern transfer mat has a transfer surface having three-dimensional irregularities and carrying a multiplicity of grains to be transferred to the substrate concrete. Concrete is cast against the transfer surface of the mat and cured in situ and the mat is then detached.
    Type: Grant
    Filed: December 15, 1992
    Date of Patent: July 19, 1994
    Assignee: Tokai Rubber Industries, Ltd.
    Inventor: Nobuo Iwaya
  • Patent number: 5328890
    Abstract: To produce more complex molded bodies from precursors of high-temperature superconductors based on the oxides of bismuth, strontium, calcium and copper, the homogeneous melt of these oxides is cast in molds at temperatures of 870.degree. to 1000.degree. C. In this process, the geometrically appropriately shaped molds are composed of a material having a melting point of at least 1000.degree. C. Finally, the molds containing solidified melt of the oxides of bismuth, strontium, calcium and copper are treated with dilute hydrofluoric acid at temperatures of 20.degree. to 90.degree. C. until the molds are dissolved.
    Type: Grant
    Filed: December 18, 1992
    Date of Patent: July 12, 1994
    Assignee: Hoechst Aktiengesellschaft
    Inventors: Eberhard Preisler, Joachim Bock
  • Patent number: 5326354
    Abstract: An improved method of producing a site for tissue ingrowth on a surgical implant by embedding a space occupier possessing a desired pattern in the surface of the implant at the desired location for ingrowth and then solubilizing the embedded space occupier to leave the pattern on the implant surface. Preferably, the implant is fabricated from a composite comprising a semi-crystalline thermoplastic resin such as polyetheretherketone or polyphenylene sulfide, and the space occupier is an acid-soluble metal plate machined to produce the desired pattern and removed by aqueous acid solution. The space occupier is embedded onto the composite surface by induction heating.
    Type: Grant
    Filed: July 2, 1993
    Date of Patent: July 5, 1994
    Assignee: Howmedica Inc.
    Inventor: Kofi B. Kwarteng
  • Patent number: 5324474
    Abstract: Thermoplastic printed wiring board spacers are fabricated by providing a water soluble partially hydrolyzed polyvinyl alcohol resin or fully hydrolyzed polyvinyl alcohol resin or a blend of partially hydrolyzed polyvinyl alcohol resin and fully hydrolyzed polyvinyl alcohol resin, the ration thereof depending upon (1) the degree of hydrolyzation of the polyvinyl alcohol resins, (2) crystallinity associated with particular polyvinyl alcohol resins, (3) the fabrication temperatures of the printed wiring board to avoid spacer melting and (4) the degree of solubility in water of the spacer. The spacers are fabricated by injection molding the polyvinyl alcohol resins or desired polyvinyl alcohol resin mixture to provide a molded configuration having a runner system with spacers attached to a sub runner system by a very thin gate.
    Type: Grant
    Filed: May 20, 1993
    Date of Patent: June 28, 1994
    Assignee: Texas Instruments Incorporated
    Inventor: Gyanendra Gupta
  • Patent number: 5301415
    Abstract: A method for forming a three-dimensional object by applying segments of complementary material and deposition material so as to form layers of material. Selected segments of material are then shaped after one or more segment is formed. In this manner, layers of material form a block containing the object made of deposition material and surrounded by complementary material. Then, the complementary material which serves as a support structure during forming is removed. Preferably, the complementary material has a lower melting temperature than the deposition material and is removed by heating the block. The deposition material and complementary material are preferably applied by thermal spray deposition but may be applied by weld deposition, liquid slurry, gravity drop or any manual means such as a hand sifter. It is also preferred but not necessary to use masks when applying the material.
    Type: Grant
    Filed: June 22, 1993
    Date of Patent: April 12, 1994
    Inventors: Fritz B. Prinz, Lee E. Weiss
  • Patent number: 5298204
    Abstract: A method of making a fused polycarbonate pattern for casting alloy structures, particularly gas-turbine blades, or components. A plurality of powder layers are fused together by a laser beam in a layer-by-layer fashion to produce the pattern. A pattern/casting mold is made and the pattern is burned out in a flash flame oven at a temperature ranging from about 1600.degree. F. to about 2100.degree. F. Preferably the burn-out step is conducted in the presence of an air stream so that the polycarbonate pattern is burned out ash free.
    Type: Grant
    Filed: February 12, 1992
    Date of Patent: March 29, 1994
    Assignee: General Motors Corporation
    Inventors: Kurt F. O'Connor, James R. Stewart
  • Patent number: 5296183
    Abstract: A method for producing a unitary part having a property enhancing coating strongly bonded to a core of either plastic or fiber reinforced composite is provided by applying the coating to a formed and shaped carrier substrate which is placed into the mold. Plastic is injected into the mold such that the plastic infiltrates the coating during molding and therefore locks the coating to the part after cure. Utilizing the present method substantially enhances the coating bond strength and reduces manufacturing costs by eliminating a post production coating step.
    Type: Grant
    Filed: August 21, 1992
    Date of Patent: March 22, 1994
    Assignee: Dow-United Technologies Composite Products, Inc.
    Inventors: John W. Carbone, Douglas M. Hoon
  • Patent number: 5290493
    Abstract: The present invention relates to a process for continuously recycling water soluble resin whereby a resin solution including about 6-12 percent by weight of resin is sprayed onto a core made of the resin. The resin used for the solution and core is selected from polyacrylic acid, copolymers of acrylic acid and acrylamide, copolymers of acrylic acid salt and ethyl acrylate, copolymers of acrylamide and acrylic acid, polymethacrylic acid, and copolymers of vinyl alcohol and vinyl acetate. The spraying of the resin solution dissolves the core to form a polymer suspension from which resin is recovered for reuse.
    Type: Grant
    Filed: October 14, 1992
    Date of Patent: March 1, 1994
    Assignee: Han Yang Chemical Corporation
    Inventor: James J. Mauro
  • Patent number: 5286431
    Abstract: A fastener of the hook and loop type intended to be incorporated into plastic articles by plastic molding processes is formed of a known separable fastener member having a base member and a plurality of engaging elements upstanding from one surface thereof. A covering which intimately surrounds the individual engaging elements protects the elements when exposed to the harsh environment of a molding process. This protecting covering is removable from the fastener after the molding process to expose the engaging elements without substantially destroying the performance thereof.
    Type: Grant
    Filed: November 16, 1992
    Date of Patent: February 15, 1994
    Assignee: Velcro Industries, B.V.
    Inventors: Donald L. Banfield, Gerald F. Rocha
  • Patent number: 5284616
    Abstract: A method for the manufacture of objects from powdered material by isostatic or pseudo-isostatic pressing. A porous body (10), with open pores in contact with the external surface(s), is preformed from a powdered material, whereupon at least one layer (11, 12) of a powdered material is applied onto the external surface of the preformed porous body by dipping. The preformed porous body is covered with a casing (13) of glass, or a material which forms glass upon heating, arranged outside the intermediate layer (12). The casing is made impenetrable to the pressure medium by heating, whereupon the preformed body is compacted to an essentially dense body. The pore system of the preformed porous body is evacuated by applying a sub-atmospheric pressure by means of at least one suction cup (21) which is applied on the external surface to be coated in connection with and during the dipping of the body in a slurry (20) of powdered materials included in the layer (11, 12).
    Type: Grant
    Filed: February 10, 1992
    Date of Patent: February 8, 1994
    Assignees: ABB Cerama AB, Sandvik AB
    Inventors: Bertil Mattsson, Jan Nilsson, Marianne Collin
  • Patent number: 5281381
    Abstract: A method for extruding polypropylene containing vinylidene chloride polymers (PVdC). According to the present invention, the polymers are extruded using extrusion equipment coated with a fluoropolymer. This method improves the processability, alleviates thermal degradation of the PvdC, improves the extrudate quality by reducing discoloration and voids in surfaces of the extruded product and protects the equipment by reducing the corrosive wear.
    Type: Grant
    Filed: November 4, 1992
    Date of Patent: January 25, 1994
    Assignee: Mobil Oil Corporation
    Inventor: Tien-Kuei Su