Abstract: The shape-dictating surfaces of the pattern are constituted by a thin self-supporting shell (4 & 5) of photocured polymer. The shell is produced by a laser controlled by a computer with reference to a design drawing. The inside of the shell is packed full of low melting-point modeling compound. The areas (6 & 7) of the pattern that do not dictate shape are demarcated by the low melting-point modeling compound.

Abstract: Para-polyphenylene sulfide, a non-composite, ultrahigh-temperature-resist, thermoplastic resin, is employed for the manufacture of interceptor motor cases. The thermoplastic resin, para-polyphenylene sulfide, has a combination of properties which are of particular interest in the fabrication of interceptor rocket motor cases. Para-polyphenylene sulfide in ribbonized form is wound directly onto the required mandrel and then fused into a solid mass. The fused, solid mass has the properties which enables it to serve as both insulator and motor case material. The manufacture of a combination insulated motor case is achieved by the following method: The equipment, first, involves the fabrication of a breakout mandrel by one of several methods. The para-polyphenylene sulfide is ribbonized by extrusion and wound down on the breakout mandrel to the required thickness and fused into a solid mass by heating to its melt temperature of about 285.degree. C.

Abstract: In the production of a hollow FRP article such as a wood type carbon black golf club head, a hollow resin shell is formed via blow molding, heat-resistant fine particles are filled as a filler into the interior of the resin shell, the interior of the resin shell is decompressed to form an inner mold, the inner mold is covered with FRP prepreg including thermoplastic resin to form a prepreg composite, the prepreg composite is heated in a metallic mold under pressure and the fine articles are removed after demolding. A golf club shaft is formed by heating a mandrel, applying thermoplastic resin powder to the mandrel and then winding a lamellar prepreg around the mandrel to thereby form a hollow shaft. A golf club is formed from a head and shaft formed as described above by enlarging the end of the shaft, placing the shaft and the head in a mold and heating the mold under pressure.

Abstract: Pyrolytic carbon products are manufactured so as to have improved structural properties. Pyrolytic carbon is deposited on a substrate in a fluidized bed of small particles at a temperature of about 1200.degree. to about 1400.degree. C., and after cooling to ambient temperature, the pyrolytic carbon is machined to desired physical dimensions for a heart valve component or the like. By heating such pyrolytic carbon structures in an inert gas atmosphere to a temperature in the range of about 1000.degree.-1500.degree. C. for at least about one hour following machining, it is found that stresses created in the pyrolytic carbon as a result of the machining are relieved without adverse effect to mechanical properties of the pyrocarbon, resulting in components having greater structural integrity.

Abstract: A method of removing a core from a molded product in which the core is formed of a particulate inert material, such as sand, bound together by a cured water soluble binder. The binder is cured by heat. The core and molded product are exposed to water, preferably heated water in a bath or steam, after the product has been molded to rapidly disintegrate the core and remove it from the molded product.

Abstract: An improved method is provided for the manufacture of tool components and the like, of a type having a hollow core disposed within an outer encasement of molded plastic material. A hollow core for the tool component is filled with a flowable filler material such as small steel pellets prior to placement of the core into a mold cavity for injection mold formation of the outer encasement. During the molding step, the filler material provides a substantially rigid structural backstop which enables a core of lightweight construction to withstand typical injection molding parameters. The thus-formed tool component is removed from the mold, and some or all of the filler material is drained from the core through an open port. In one embodiment the tool component includes a lightweight hollow tool handle; in another embodiment, the tool component includes the head of a deadblow hammer with a portion of the filler material retained therein.

Abstract: A method and process for computer-controlled manufacture of three-dimensional objects involves dispensing a layer of liquid, insoluble material onto a platform at predetermined locations, which then hardens. A second media, preferably water soluble, is then sprayed onto this layer to thereby encapsulate the hardened insoluble media. The uppermost surface of this encapsulant is planed, thus removing a portion of the encapsulant to expose the underlying insoluble material for new pattern deposition. After the resulting planing residue is removed, another layer of liquid, insoluble media is dispensed onto the planed surface. The insoluble media can be of any color and may vary from layer to layer, and from location within a layer to location within a layer. These steps are repeated, until the desired three-dimensional object, surrounded by a mold, is completed. At this point, the object is either heated or immersed in a solvent, thereby dissolving the mold and leaving the three-dimensional object intact.

Abstract: A device for injection moulding plastic articles by the fusible-core technique includes a unit (1) for moulding fusible cores, a unit (2) for injection moulding, a unit (3) for melting and for recovering the fusible cores and a unit (4) for washing the moulded parts. The first two units are served by a mobile transfer robot (5) equipped with a rotatable arm having a ripper adapted to catch a fusible core and a gripper adapted to catch a moulded part. The two latter units are served by a stationary robot for melting (8) which interacts with the transfer robot (5). By programming the various functions performed by the robots, it is possible to carry out in parallel the moulding cycles of fusible cores and of injection moulding of the desired parts with a minimum of non-productive time and hence to obtain an automatic production with a high yield.

Abstract: A casting method for manufacturing various types of ceramics products having an intricate configuration and a partly diversified wall thickness, such as compressor scroll blade and a screw rotor, by casting a slurry including ceramics, etc. in a mold, includes an arrangement wherein the mold is partly or entirely formed of a flexible gel material which can be melted by heating at a temperature lower than the boiling point of the dispersion medium, whereby the stresses generated when molding the product can be mitigated. Thus, the molding of a product having a high level of dimensional accuracy can be carried out with ease.

Abstract: A unitary jet impingement plate is formed including a body portion thereof and at least one manifold integrally connected with the body portion, each having internal passages in fluidic communication with one another. At least one jet impingement orifice is provided through a plate of the body portion of the jet impingement plate through which heat transfer fluid can be directed into a fluid jet of such heat transfer fluid from the jet impingement plate and for impinging on a component or object to the thermally effected thereby. The heat transfer fluid may be heated or cooled as required depending on the specific application. Preferably, the jet impingement plate is structurally enhanced by the provision of integral posts provided in a pattern within the body portion of the jet impingement plate. More preferably, a plurality of jet impingement orifices are provided in accordance with a predetermined pattern designed for a particular application.

Abstract: A method of removing a core from a molded product in which the core is formed of a particulate inert material, such as sand, bound together by a cured binder of a water soluble carbohydrate alone or mixed with a silicate is disclosed. The silicate is preferably an alkali earth metal silicate, preferably sodium silicate, and the carbohydrate is preferably a saccharide or starch. The binder is cured by heat. The core and molded product are exposed to water, preferably heated water in a bath or steam, to rapidly disintegrate the core and remove it from the molded product.

Abstract: A process for making a silicon carbide foam structural material utilizing continuous and non-continuous processes where bead members are mixed with silicon powder-carbon powder and molded into a shape. The bead members are then removed by melting. The remaining silicon powder-carbon powder structure, having been formed with a plurality of apertures therein from where the beads have been removed, is further heated to a point sufficient to form a silicon carbide structure retaining such plurality of apertures to create a silicon carbide foam.

Abstract: A method for isostatic pressing of formed powder, porous powder compact, and composite intermediates and the intermediate and final products produced thereby. The method includes the steps of:(A) coating the exposed surface of the formed powder, porous powder compact, or composite intermediate with a flowable film-forming material capable of forming a solid continuous impervious flexible film; then(B) solidifying the coating of step (A) on the surface of the intermediate to form a coated intermediate; and(C) subjecting the coated intermediate of step (B) to a uniformly applied pressure exceeding atmospheric pressure to produce a flexible coating formed directly on the parts to be isopressed, permitting small parts or parts with complex shapes to be coated individually or in bulk.

Abstract: Thermoplastic cores reinforced with strong magnetic shots or/and particles are molded and then thermosets are molded around this thermoplastic core. The thermoplastic core is decored by a magnet at a high temperature above the softening point of thermoplastic matrix to produce a hollow curved internal space.

Abstract: A method of forming a fastener member having a base and a plurality of headed stems arranged in columns and rows and projecting from the base. The fastener member is formed by injection molding a molten material into a base mold, sacrificial stem mold and head mold, wherein the material is solidified. After the base mold and head mold are removed, the stem mold may be destructively removed to release the fastener member.

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. A conventional polymeric resist process may be used to deposit a pattern of high temperature resist material. With the high temperature resist in place and the polymeric resist removed, a high temperature deposition process may proceed without degradation of the resist pattern. After a desired film of material has been deposited, the high temperature resist is removed to leave the film in the pattern defined by the resist. 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.

Abstract: A process for producing a sturdy refractory metal oxide article includes the steps of heating a substrate of organic material impregnated with a metal compound to thermally decompose the compound without substantial thermal decomposition of the substrate, further heating to decompose and remove the organic material and complete conversion of the compound to a metal oxide so that a metal oxide replica of the substrate remains and further heating to sinter and densify the replica such that the replica has a strength (shock resistance) figure of merit of at least three g-meters and the replica retains such strength after heating to 1500 C.

Abstract: A method of manufacturing thin film magnetic heads. One embodiment of the present method features the step of placing a separating layer on a substrate and placing subsequent element layers of one or more thin film magnetic heads on the separating layer. Upon imposition of separating conditions, the thin film magnetic head is released, allowing the substrate to be reused.

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: A superconducting pattern formed from a superconducting ceramic film is illustrated. The pattern is made in the form of a coil which is embedded in an insulating ceramic film. The insulating film is made of a ceramic material whose thermal expansion coefficient is approximately equal to that of the coil.

Abstract: Process for the production of a component, in which metal or ceramic powder (6) is applied under centrifugal force to the inner wall of a gas-permeable mold (13), which is under reduced pressure and is located in a reduced-pressure vessel (10), and precompacted, after which the mold (13) is removed from the vessel (10) and sintered. The mold (13) consists of a heap of ceramic grains with an organic binder having high strength between room temperature and a temperature just below the sintering temperature, in order to support the powder (6) to be sintered to give the component. When sintering starts, the binder evaporates or burns away, as a result of which the mold (13) substantially loses its supporting action for the component. Binder: aminolic, phenolic, furan resin.

Abstract: A process for obtaining precision castings of body parts wherein the body part is first immersed in a ice and water slush, immediately removed therefrom and immersed in a melted paraffin wax-water container, immediately removed therefrom and the body part extracted from the resulting wax mold. At least the interior surface of the hollow wax mold is coated with a casting material and permitted to cure at room temperature. The cured casting is heated by immersion in the wax-water container or in a separate heated water container for a period of at least ten minutes to remove the wax mold and recover a casting of the body part. The removed wax molding material may be recycled and employed in subsequent castings and recover a casting of the body part.

Abstract: A method for manufacturing a plastic hollow product with complicated geometry using water soluble resin. The method includes the steps of making a half shell of the core out of the water soluble resin, joining the half shells together into a piece by solvent welding, ultrasonic welding, vibration welding, or the like, overmolding the core with water resistant resin, and dissolving the core away from the overmolded product by spraying hot water thereto. The injection conditions such as injection time, injection speed, and injection pressure are varied in the respective zone which is divided into several divisions by same distance in the injection cylinder. Therefore, injection procedure is performed in a stepwise manner to make a hollow product.

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.

Abstract: The method includes mixing (100) degradable consumable cores (11) with a liquid coating composition (20) including an aqueous solvent (21), a hydrosoluble resin (22) and an anti-agglomerant additive (23), drying (200) the coated cores so as to obtain free balls (12) with a substrate film (2), mixing (300) these balls (12) first of all with a liquid covering substance (30) including a synthetic base product (31) and optionally an auxiliary product (32), then with an anti-agglutinant adjuvant (33), drying (400) the covered balls so as to obtain free ball structures (13) with a covering layer (3), and stoving (500) these ball structures so as to harden their covering layer and degrade the cores and thereby obtain hollow spherules (10). Application in the manufacture of intermediate products for producing in particular energy absorbers.

Abstract: A method of manufacturing a free standing perovskite lead scandium tantalate film. A film of lead scandium tantalate is formed on a layer of MgO deposited on a sapphire substrate. The MgO layer is etched by phosphoric acid thereby releasing the lead scandium tantalate film from the substrate.

Abstract: A flow cell for optically analyzing a liquid sample is coated with a fluoropolymer having a refractive index less than the refractive index of water.

Abstract: Process for obtaining three-dimensional objects, according to which process a sheet (2A, 2B, 2C) is prepared, which sheet is composed of a material, the solubility of which varies when it is subjected to a specific radiation, and of fibers or of a screen for reinforcement, the sheet having a sufficient rigidity to be handled and being capable of adhering on a similar sheet. The sheet is subjected to said radiation (18) in a defined zone, and then a new sheet is fixed onto it and the passing of radiation is recommenced, and then the stack is subjected to a selective dissolving which causes the desired object (31) to appear.

Abstract: The present invention is a wax-based material for use in the lost wax process where the wax must be capable of withstanding temperatures of up to 350.degree. F., the wax-based material including: (a) a high temperature brittle wax; (b) about 5-30 wt % organic plasticizer including polyfunctional amines and alcohol amines and (c) about 5-10 wt % paraffin wax.

Abstract: A core for producing a molded resin product having a bent hollow portion, including two-forked and multi-forked products used as parts for automobiles, and a process for producing the aforesaid resin product having a bent hollow portion by using said core.

Abstract: A fibrous material is placed at a desired place on a preliminarily ceramic shaped body and ceramic powder added thereto. The preliminarily ceramic shaped body, ceramic powder and fibrous material subjected to mold pressing and then to cold isostatic pressing. The resulting shaped material is subjected to removal of the fibrous material and then to firing, thereby a ceramic having desired perforations can be produced.

Abstract: A multiple metallic core assembly for use in production of a plastic injection-molded component is formed by injecting molten metal alloy into a core die at a fill stage of an indexing system, indexing the core die through a cooling stage to an unloading stage, and removing the core from the core die and inserting the core in one of a plurality of locations of the core assembly. Individual cores are continued to be formed as discussed above until all the locations of the core assembly are filled, and the core assembly is complete. Therefore, the core assembly is removed and transported to a plastic molding machine to produce the plastic component. Then, the core assembly is melted out from the plastic component in hot oil, and the molten metal alloy produced thereby is returned to a molten metal alloy tank.

Abstract: A method for forming a high T.sub.c metal oxide superconductor in the form of a hollow fiber. The method includes the steps of: forming a polymer-metal complex precursor; filling a decomposable hollow fiber mold with the precursor; and heating the filled mold to decompose the mold and convert the precursor to a metal oxide superconductor in the form of a hollow fiber. Ag-doped metal oxide superconductor structures can also be produced by the above method.

Abstract: A mold and method for forming a balloon for dilatation catheters, particularly balloons with a prismlike shape with a transverse polygonal cross section when the internal pressure is at atmospheric conditions. Upon inflation to higher internal pressures, the balloon assumes a normal circular cross section. The balloon shape is particularly suitable for balloons formed of polyethylene terephthalate and the like which are not readily heat settable. Reduced deflated profiles are obtained. The mold is formed by first making a preformed core member which has the shape and dimensions which are desired for the balloon. A heat-formable tubular member, preferably formed of borosilicate glass such as PYREX, is disposed about the core member, subjected to heat and an internal vacuum so as to be shaped onto the exterior of the core member.

Abstract: A method of making a shell mould, particularly for a lost wax casting operation, includes the deposition of an adhesion agent on the pattern before the deposition of layers of ceramic material to build up the mould. The adhesion agent used is preferably a 3% solution of aminosilane in a solvent consisting of ethanol and ethyl acetate in amounts from 25% to 75% of the solvent. The method avoids the phenomenon of detachment at the pattern/ceramic interface.

Abstract: A mold, having a mold cavity commensurate with the shaping, forming or welding to be made, includes an RF energized heater in close proximity to the mold cavity for heating plastic tubing placed within the mold cavity to a temperature sufficient to shape, form or weld the plastic tubing. An RF generator, electrically connected to the RF energized heater, monitors the power applied as a function of the temperature of the heater to heat the plastic tubing to a precise temperature. The mold is of thin wall construction with minimal thermal inertia to expedite both heating and cooling. Various configurations of the mold may be made to form tip shaping, forming or welding, butt welds, annular welds and the like to weld single thermoformable elements or join multiple thermoformable elements.

Abstract: Method of producing a mold from a ceramic composition which can be washed-out with water after use thereof in a molding process, the method including forming a ceramic composition by mixing from about 30 to about 80 weight percent of at least one hemihydrate including alpha-calcium sulfate hemihydrate or beta-calcium sulfate hemihydrate, from about 5 to about 45 weight percent of fire clay, and from about 5 to about 25 weight percent of at least one silicate-based filler. About 100 parts by weight of the ceramic composition are mixed under stirring into from about 46 to about 54 parts by weight of water to form a slurry. The slurry is poured into a formation mold suitable for forming the desired mold and the slurry contained in the formation mold is allowed to set and form a set body. The set body is then removed from the formation mold and dried to provide the mold.

Abstract: Apparatus for and related methods of forming three-dimensional objects out of a building material, which is normally solid but which is flowable when heated. In one embodiment a support material is used to fill in portions of layers which are not to be solidified as part of the object to provide support to otherwise unsupported portions of other layers. Advantageously, the support material is also normally solid and flowable when heated, and has a lower melting point than the building material enabling the support material to later be removed without damaging the object. In an alternative embodiment this support material can be used to build a support such as a web support or the like for supporting an object surface from a second surface.

Abstract: A process for producing a cylindrical reinforcing fibrous molding by sealing openings at opposite ends of a porous cylindrical disintegratable mold, immersing the mold into an aqueous solution of a molding material containing reinforcing fibers and an inorganic binder, and depositing the molding material onto the outer peripheral surface of the mold by applying suction within the mold to form a molding blank; pressing the molding blank against the mold to adjust the shape of the molding blank; disintegrating the mold to remove it from the blank; and heating the molding blank to partially bond the reinforcing fibers with the inorganic binder.

Abstract: A method of molding complex composite articles having skin portions containing fibres to be injected with a resin and a core portion includes providing one or more galleries in the core or fibre skin and injecting resin into the gallery or galleries whereby it is rapidly transmitted to all portions of the skin. The galleries overcome the resistance to flow created by the capillary nature of the fibrous layer and enable more rapid mold cycles to be employed and more complex articles therefore to be molded.

Abstract: Fiber reinforced resin composite structures are cured and fully consolidated while compensating for incomplete initial compaction of prepreg between cores, and the mandrel's thermal growth which spreads the cores apart by forming the structure around a metal alloy form fastened to a mandrel wherein the coefficient of thermal expansion of the metal alloy is greater than that of the mandrel.

Abstract: Sand cores are removed from metal or plastic coatings by exposing the cores to a humid atmosphere for a sufficient time to weaken the binder of the sand cores. The sand is then shaken from the casting. Metal or plastic castings with hollow passages are produced by forming a casting around the sand core bound with a suitable binder followed by exposing the casting and sand core to a humid atmosphere and then shaking the sand from the casting.

Abstract: A method and apparatus for forming a three-dimensional object by thermal spraying utilizes a plurality of masks positioned and removed over a work surface in accordance with a predetermined sequence. The masks correspond to cross sections normal to a centerline through the workpiece. One set of masks defines all cross sections through the workpiece. A second set of masks contains at least one masks which corresponds to each mask of the first set. Masks from each set are alternatively placed above a work surface and sprayed with either a deposition material from which the workpiece will be made or a complementary material. In this manner, layers of material form a block of deposition material and 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.

Abstract: A method of sealing a concrete joint formed between a pair of concrete castings by creating an injection hole wherein a removable frame member can be attached to the bottom surface of the first concrete casting so as to form obtuse angles with the concrete casting surface. The other concrete casting is then cast around the frame member. The frame member is then removed to form the injection hole of the desired configuration, and sealing material can then be inserted into the injection hole for feeding into, and sealing of, the joint.

Abstract: A method of making a femoral rasp wherein the hip stem implant is used to make a two part mold. The mold halves are separated and the implant removed to yield left and right mold halves representing corresponding halves of the hip stem. The cavities of the mold halves are lined with wax and a plurality of blades are imbedded into the wax such that an anchor portion of each of the blades remains exposed. The mold halves are connected together and a stem of handle is inserted therein. A moldable material such as PMMA is poured into the mold and allowed to cure. When the PMMA is hard or cured, the mold halves are separated and the wax is removed from the rasp body exposing the cutting surfaces of the teeth.

Abstract: In connection with a device for casting lead grids for electric battery plates, a highly porous ceramic mold lining, preferably of zirconium oxide, is prepared by flame-spraying. Such a lining can include a thin surface coating on a profiled, basic metallic mold or a separately prepared insert plate which is retained to a metallic mold molder. The ceramic surface coating may be accurately formed in place, or may be formed as an over-spray which is then reduced in thickess. Formation of the surface coating may be accomplished by placing masks on the basic metallic mold during the flame spraying, for those areas of the grid which tend to accumulate material, or by adjusting an initially coarse profile of the ceramic layer to the exact profile of the casting by a material-removing treatment.

Abstract: A method and apparatus for injection molding of ceramic suspension is disclosed wherein an elastomeric bladder is disposed within a mold cavity of a mold. The elastomeric bladder, in a relaxed state, can be tubular or can be formed by bonding together sheets of material. A ceramic suspension is injected into the elastomeric bladder, whereby the elastomeric bladder is distended. Distention of the elastomeric bladder applied a significant force to the ceramic suspension for preventing jetting and formation of knit lines within the ceramic suspension. The ceramic suspension distends the elastomeric bladder until the mold cavity is filled. The ceramic suspension is then exposed to conditions sufficient to cause the injected ceramic suspension to form a molded ceramic greenware composite. The molded ceramic greenware composite can then be removed from the mold for drying and for debindering and densification to form a finished ceramic part.

Abstract: A process and device for producing a rubber tube having a smooth outside surface in which a molten synthetic resin is heated from the inner circumferential side immediately before it flows from a die along the periphery of a rubber material layer and the rubber mentioned is cooled within the die.

Abstract: The plate-like valve elements (10 and 20) of the microvalve are provided with a plurality of valve seats and, respectively, corresponding valve members. The sealing surfaces of a secondary valve element (10) are respectively formed by molding to copy the sealing faces of a primary valve element (20) so that the sealing surfaces of both valve elements are completely complementary to each other. The sealing surfaces need no further processing such as machining. Despite liberal tolerances of manufacture a high precision register of the valve elements in relation to each other is ensured.

Abstract: A method is disclosed for making free standing multilayer films by depositing the films on a soluble substrate. The substrate solvent combination is chosen so that the solvent will not effect the multilayer materials. After deposition on the substrate, the multilayer films are cemented to a flat and smooth frame, in which a hole or window of the desired size and shape has been previously drilled. The adhesive, the films and the frame are insoluble in the chosen solvent for the substrate. After the adhesive is set, the substrate is dissolved leaving the multilayer film free standing within the frame. Also disclosed is a method for providing the films with a curvature.