Abstract: A method of fabricating a composite structure having at least one skin molecularly bonded to a core. A skin is provided of reinforcing fibrous material and a thermoplastic matrix. The skin is thermoformed to the general exterior shape of the composite structure. A core having a thermoplastic matrix complementary to the matrix of the skin is molded into the general shape of the composite structure. The skin and the core are placed in juxtaposition in a final forming mold. A thermoplastic material is injected into the final forming mold under isostatic conditions. The thermoplastic material is complementary to the thermoplastic matrices of the skin and the core.

Abstract: A process is provided in which a plasticized resin is extruded from an extruding machine into an accumulator into which the resin is stored by an amount which exceeds the amount required for one resin molding operation. The stored resin, in operation, is fed through a flexible hose to a supply and measuring device, such as a gear pump, under controlled pressure conditions. The resin is measured by the supply and measuring device by regulating the flow rate of the resin and is then charged into the mold cavity in a measured amount. The clamping of the mold can be effected by a clamping force less than that required by a conventional press-molding machine.

Abstract: A method of making a fire hose including the steps of extruding a tube having inner 12 and outer coverings of elastomeric material on a woven jacket made from woven synthetic textile yarns and having a weft which is unusually highly crimped. The extruded tube is placed in a confining mould or sheath having an internal diameter substantially the same as the external diameter of the hose, curing the material of the tube by internal application of heat and pressure, pressing the outer covering into tight engagement with the sheath. The sheath effectively prevents radial expansion of the hose during the curing and the outer covering is thus embossed with the surface topography of the inner surface of the sheath upon removal of the sheath. The hose thus formed has good diametral swell properties and consequently reduces the frictional forces in relation to the amount of water flowing through the hose.

Abstract: A method of apportioning the quantity of material in the manufacture of molded products made from hardenable molding compounds in which a resin mat panel is cut into individual cut pieces which are stacked into mat packets and fed to the tool of a parallelism controlled press equipped with a path measuring system for measuring the distance between the clamping plates. The mat packets are compacted to become the molded products. A constant molded product volume is realized by measuring the thickness of the molded product at a defined point in time by means of the path measuring system and the measured values are used as regulating values for regulating the size of the cut area of each cut piece.

Abstract: A method of molding a cup-shaped article such as integral vehicle wheel rim and disc segment, wherein a plurality of sections of resin-impregnated cloth are placed over a substantially cylindrical mandrel. The cloth sections are substantially identical and have circular central portions which are stacked on the mandrel end face, and oppositely projecting wings which are draped over and are circumferentially staggered around the mandrel sidewall. The central axis of each sheet section is at an angle of 45.degree. to the warp and weft fibers of the section cloth. The sheet sections thus form a mold charge which is compression molded to form an integral vehicle wheel rim and disc segment.

Abstract: Forming tools are arranged inside a metallic caisson formed by means of open boxes provided with nesting portions. The forming tools are connected to a microwave generator and are made of a material with a small absorption capacity for the microwaves and adapted for supporting pressure within the range of 50 to 200 bars. The forming tools have working faces of a shape mating that of a work piece to be obtained.

Abstract: This invention involves polyethylene blends prepared by a particular method to achieve a unique solid state processability. More specifically, the polyethylene blends of this invention are high density polyethylenes (HDPE) blended in solution with a minor fraction of branched low density polyethylene, linear low density polyethylene or other polyethylene copolymers with a melting point significantly lower than that of HDPE. The HDPE blends described herein possess a unique large scale deformation characteristics below the melting pointing of the major HDPE component, such that the HDPE blends are suitable for solid state processing such as stamping or forging, etc.

Abstract: A method of making a high strength carbon-carbon utilizing a solid flowable particulate polymer as a pressurizing medium. A resin impregnated carbon fiber reinforced prepreg is disposed in a pressure vessel and the vessel is substantially filled with a solid flowable particulate polymer. The prepreg is exposed to sufficient temperatures and pressures to cure the prepreg to form a carbon-carbon precursor which is subsequently exposed to temperature and pressures sufficient to post-cure the carbon-carbon precursor. The post-cured carbon-carbon precursor is exposed to temperatures and pressures sufficient to carbonize said post-cured carbon-carbon precursor to form a carbon-carbon composite.

Abstract: A method and apparatus forms a plastic part having a shape memory which has been formed to a second shape from an initial shape by the application of pressure to cause molecular orientations which are subsequently fixed by being cooled to a desired temperature and, when subjected to subsequent energy such as heating, will eliminate the molecular orientation and create a restoring force to return the part to the initial shape.

Abstract: A composition consisting of an intermetallic compound, molybdenum disilicide, which is reinforced with VS silicon carbide whiskers dispersed throughout it and a method of making the reinforced composition. Use of the reinforcing material increases fracture toughness at low temperatures and strength at high temperatures, as compared to pure molybdenum disilicide.

Abstract: A hot-pressed ceramic composite having good resistance to thermal shock and good erosion/corrosion resistance in molten alloys, and a method for producing said composite which comprises the blending of fused zirconia mullite with boron nitride.

Abstract: A method of making fiber reinforced composite articles from stabilized dry fiber preforms which are impregnated with a thermosetting resin by the resin transfer molding method. The dry fiber preforms may be stabilized prior to molding by dispersing a polymeric binder between adjacent dry fabric plies of the preform. Hot air is passed through the preform after it has been compressed to fuse the binder and bind the dry fabric plies together, forming a stabilized high density fiber preform. Forming a preform by this method is significantly less labor and time intensive than methods currently in use.

Abstract: This invention is directed to a thermal barrier layer particularly adapted for insulating a solid flowable particulate polymeric pressure transfer medium from elevated temperatures during high temperature molding. A method useful with the thermal barrier comprises transferring pressure from a pressure means via the thermal insulation layer to an article and exposing the article to temperatures of about 316.degree. C. to about 1371.degree. C. An exemplary thermal barrier comprises at least two flexible layers of beads having a thermal insulation of less than about 2 k.

Abstract: An annular chromium carbide coating on an annular sealing surface of a stainless steel sealing assembly component for use in a nuclear reactor coolant pump, is treated by encasing at least the chromium carbide coating on the stainless steel sealing surface by applying a metallic cover thereover, evacuating the atmosphere between the cover and the coating on the sealing surface, hot isostatic pressing the stainless steel sealing assembly component and the chromium carbide coating thereon encased by the cover, cooling the sealing assembly component and the coating thereon encased by the cover, and after cooling thereof removing the cover from the coating. The result is a chromium carbide coating on the sealing component substrate densified substantially to its full theoretical density (greater than 99%) and metallurgically bonded by the hot isostatic pressing to the substrate exterior surface.

Abstract: A resin-molding tablet for use in resin-molding semiconductor devices has a tablet body formed of powdered or particulate resin. The particles of the resin are compacted such as to form voids between adjacent particles. At least the outer peripheral region of the tablet is fused such that the resin particles are welded together to form a continuous layer of fine and impervious structure substantially free of open pores. The internal air trapped in the voids of the tablet is drawn and removed before the tablet is fused so that the tablet is substantially free of air. The tablet is produced by placing a particulate or powdered resin material in a vacuum vessel so as to allow the internal air in the resin material to be drawn outside, and then applying pressure and heat to the resin material so that at least the peripheral region of the mass of the particulate resin is fused to weld together.

Abstract: Crystallizable mainly amorphous thermoplastic material is crystallized at a temperature exceeding the glass transition temperature of the material (13) by subjecting the material at the elevated temperature to compressive forces. The material thickness as a rule is reduced by at least 20%, preferably by at least 40%. To achieve this a plunger (20) and a mould (30) are moved to a minimum distance at which the thermoplastic material (13) located between the plunger and the mould part is subjected to compressive forces. The plunger and/or the mould part are provided with elements (29, 39) for the setting and maintaining of a temperature specified in advance of the surfaces (23, 33) by which the plunger and the mould part respectively abut against the thermoplastic material.

Abstract: A method of making an object of superconductive material in the form of an oxide by isostatic pressing of a body preformed from a powder material with an oxygen-containing pressure medium at a temperature required for sintering of the preformed body, the powder material is an oxide of the metals contained in the superconductive material. Before the isostatic pressing is carried out, the preformed body is surrounded by a gas-tight casing with the ability to transport oxygen.

Abstract: A method of applying a mold-releasing agent to the molding surfaces of a mold after cleaning the surface. This method involves inserting a mold-releasing sheet between said molding surfaces of a mold coating the molding surfaces with the mold releasing agent by heating and pressing the mold-releasing sheet to cure it, and removing the cured sheet from the molding surfaces of the mold. This mold-releasing sheet is composed of (i) uncured rubber, (ii) a curing agent, and (iii) a mold releasing agent. The uncured rubber can be selected from a group consisting of chloroprene rubber, butadiene rubber, nitrile rubber, ethylene-propylene terpolymer rubber, styrene-butadiene rubber, polyisoprene rubber, butyl rubber, silicone rubber, and fluoridated rubber.

Abstract: Fiber reinforced thermoplastic parts having good surface characteristics are produced by a process involving: preheating fiber reinforced composite to achieve at least a flowable viscosity of the polymer, and (2) molding under controlled rheological conditions. The preheating is conducted on composites that are predominantly amorphous thermoplastic polymers, copolymers, polyblends or alloys reinforced with continuous glass fiber strand reinforcing mat. The amount of the mat present in the laminate is less than around 40 weight percent of the composite. The temperature of preheating is at least greater than the glass transition temperature of the polymer and less than the degradation temperature of the polymer to expand the composite.

Abstract: A tire tread (74,76,194) is injection molded by increments in a mold cavity (56,58,119,224,262) having an open end (110,272) closed by a trailing end (116) of a cured section (114,228). A temperature moderating closed end (109,207,268) prevents complete curing of a trailing portion (116) of the cured section (114,228) while the rest of the section is cured. The mold (14,16,90,188,236) is opened so that the cured section (114,228) may be shifted to a position where the trailing portion (116) is clamped in the open end (110,272) of the mold cavity (56,58,119,224,262). A second section (118,228,264) is injection molded in the cavity (56,58,119,224,262) and the partially cured trailing portion (126) of the cured section (114,228,264) is cured and adhered to the leading portion (130) of the second section (114,228,264) as the second section is cured. This process may then be repeated for later sections to provide a desired length of cured tire tread stock (74,194,264).

Abstract: A method of making a silicon nitride comprising object by use of a low density reaction bonded body is disclosed. An uncompacted mixture of silicon powder and a fluxing agent is heated in a nitrogen atmosphere to react the mixture with the atmosphere to form a body consisting essentially of silicon nitride and having a dimension greater than and a density less than the finished product. The nitrided mixture is then hot pressed to produce a silicon nitride comprising object of desired dimension and density, which material is useful as a cutting tool material for machining metals.

Abstract: A method and apparatus for manufacturing compression molded articles from a thermoplastic material blank comprising heating the material, and compression molding the blank by means of a die. The material forming the blank is deposited on the surface of an intermediate support which forms a part of the compression molding mold and extends under and is separated from the die. The blank is separated from the die, which may be accomplished using a heated stream of gas surrounding the die and directed at the point of separation. The blank is introduced into the mold which is closed as the intermediate support is lowered, followed by compression molding the blank by the application of compression molding pressure, and cooling the molded article at least partly under pressure.

Abstract: In an installation for producing packaging containers such as tubes, from prefabricated tube bodies and end portions of thermoplastic material, which are connected to the tube bodies, a plurality of moulds which are moved on a circulatory path each include an upwardly directed female mould portion and a mandrel which is pivotable about a horizontal axis between a downwardly directed working position and a loading position. A tube body loading station, a material feed station having a nozzle, and a container unloading station are arranged at spacings from each other along the circulatory path, while the female mould portion and the mandrel of each mould are displaced relative to each other on a common working axis. In a plurality of working units including support frames which are moved on the circulatory path, each support frame supports at least the female mould portion and the mandrel of a mould and the actuating mechanism thereof.

Abstract: A process for moulding articles of fibre reinforced plastics material which includes pre-heating a sheet of consolidated thermoplastics material which has dispersed therein from 20% to 70% by weight of reinforcing fibres which have a high modulus of elasticity (as herein defined) and between about 7 and about 50 millimeters long to cause the sheet to expand due to relief of the stresses in the reinforcing fibres, placing the expanded sheet in a compression mould and closing the mould to form an article of predetermined shape having portions of different density.

Abstract: Extrudable pharmaceutical mixtures are tableted by a continuous method in which the mixture is extruded and the still deformable extrudate is pressed between two rollers which are driven in opposite directions and possess depressions opposite one another in the roller shell, the form of these depressions determining the tablet shape.

Abstract: The present invention provides a method for preparing a molded article of an ultra-high molecular weight polyethylene which is characterized by compression-molding, or heating and pressurizing a porous sheet of said ultra-high molecular weight polyethylene. The porous sheet may be superposed with a substrate, and may be wrapped around a deformable member of a mold and densified by deformation of said member.

Abstract: Rare earth oxysulfide ceramic material prepared by covering the material with a foil of a metal selected from the group consisting of molybdenum, tungsten, platinum, and rhenium, sealing it into an airtight vessel of tantalum or niobium, and then subjecting it to a hot isostatic press process.

Abstract: A method of making a reaction bonded/hot pressed silicon nitride comprising object is disclosed. Second phase crystallites are formed prior to hot pressing. A mixture of silicon, SiO.sub.2, and 0.4-2.3 molar percent (by weight of the silicon) of oxygen carrying agents, i.e., Y.sub.2 O.sub.3 and Al.sub.2 O.sub.3, is performed and reaction nitrided to form discs or billets having at least 60% alpha Si.sub.3 N.sub.4 and a high proportion of second phase crystallites which displace substantially all silicate glass except for a controlled small quantity. The reactive amounts of Y.sub.2 O.sub.3, Al.sub.2 O.sub.3 and SiO.sub.2 are controlled to assure formation of substantially Y.sub.1 SiO.sub.2 N as the second phase crystallite. Al.sub.2 O.sub.3 is controlled in an amount of 0.4-4% by weight to ensure that the small proportion of glass serves to protect the oxynitrides against linear oxidation kinetics. The hot pressed material has no visual mottle porosity associated therewith.

Abstract: The invention relates to producing relatively flaw free zirconia ceramic shapes requiring little or no matching by superplastic forging of a fully sintered or partially sintered preform. The preform is prepared by providing a starting powder comprising by weight from about 70% to about 100% zirconia and from about 0 to about 30% of stabilizing additives, e.g. commerically available TZ-3Y powder, cold pressing to obtain a preform of green density ranging from about 30% of theoretical density to about 75% of theoretical density and partially or fully sintering at atmospheric pressure, e.g. in argon or air at a temperature ranging from about 900.degree. C. to about 1900.degree. C. The superplastic forging is carried out by isothermally pressing the partially or fully sintered preform into substantially final shape utilizing a temperature and strain rate such that surface cracks do not occur, e.g. utilizing a temperature of 1310.degree. C.

Abstract: A method of molding oriented structural yarn/polymer matrix composite structural articles in which a preform of oriented yarn layers saturated with a resin is placed in a shape-defining mold, which is put in an enclosure, and subjected to heat and pressure to cure the resin, after which a cooling medium may be introduced. To enable the use of lightweight multi-part molds, and a mixture of pressure is distributed evenly, an internal liner is collapsed about the mold prior to curing. The process is extremely productive, and allows for accuracy and reproducibility through the use of real time temperature monitoring and closed loop feedback control.

Abstract: Improved methods of preparing molded thermoplastic articles are provided. The methods are basically comprised of the steps of admixing a radio frequency energy sensitizing agent comprised of N-ethyl toluenesulfonamide with a thermoplastic polymer, applying radio frequency energy to the mixture formed for a time sufficient to produce a moldable consistency in the mixture, and then compression molding the mixture to produce a molded article therefrom.

Abstract: A method for checking or controlling cross linking in products made of elastomeric material has a mold of a fixed volume provided with at least one pressure sensor detecting pressure variations in the mold during cross linking in order to obatin data referring to the progress of the cross linking in the case of laboratory applications, while in manufacturing, it can provide an automatic control of the duration of the various states of the manufacturing cycle by means of microprocessor controlled equipment to which such sensors are connected. The peak pressure reached in the mold is measured and a decrease in its gradient as time passes is detected. Subsequently an increase in the gradient is detected and the time required to obtain a variation of a pre-established order is determined. This data is used to obtain information on how cross linking is progressing and for automatically controlling the manufacturing equipment.

Abstract: In a method for producing shaped synthetic members, one begins with superficially plasticized synthetic granulated material in manner known per se. This is sintered to form a preform in a first operation in a preliminary chamber. The preform is then extruded by way of a narrow nozzle into a moulding cavity, the nozzle cross section being so narrow that on the way between the preliminary chamber and the moulding cavity, the individual granular particles must be deformed mechanically. The moulding cavity is then filled by one or more thin strands, which consist of solid, but mechanically deformed and superficially plasticized granulated particles.

Abstract: A method for making an article, such as a plastic food container lid having frangible score lines. The article is formed of a sheet of plastic material having substantially constant thickness with score lines defining an offset portion thereof which is connected to the remaining sheet material by a segment that is thinner than the sheet material and being rupturable for the removal of the offset portion. The periphery of the inwardly directed portion of the offset portion overlaps the periphery of the outwardly directed portion of the offset portion on the opposite side of the sheet material. The fracturable score lines are corrugated along their length by a plurality of successive grooves and ridges with the grooves extending deeper into the material than the ridges.

Abstract: The heat-sink capacity of a thick-walled article being cured with a hot liquid supplying heat to one side of the wall, allows the point of least cure (PLC) to receive a higher rate of cure equivalents even after the hot liquid is replaced with a cold liquid. In the mean while, on the other side of the wall continues to be heated. Because such a change-over is effected before the PLC has received the minimum number of cure equivalents required to effect a cure at the PLC (a "pre-cure change-over"), a valving arrangement is provided which allows the changeover to be effected without permitting a pressure drop in the bladder sufficient to permit the tire to "blow" because it is as yet uncured when the change-over is effected. Such a pre-cure change-over cannot be made when steam is replaced with water at ambient temperature.

Abstract: Detergent bars (soap or non-soap) are stamped or imprinted using a die or dies having a modulus of elasticity in the range 5.times.10.sup.5 to 1.times.10.sup.7 Nm.sup.-2. This gives reduced adhesion of detergent to die, reduced die-blocking and consequently reduced marring of bars. Preferably each such die has a facing layer of elastomer so as to achieve the desired low modulus of elasticity which preferably is distinctly less than that of the detergent.

Abstract: A shaped article of superplastic ceramic composed of zirconia toughened ceramic containing, or not containing, fine alumina powder is produced by deforming the ceramic under the action of stress at a temperature in the range of superplastic temperatures thereof.

Abstract: A method of making a synthetic resin food container having a bottom wall, a side wall extending at an obtuse angle to the bottom wall and a rim or legs extending from the undersurface of the bottom wall. A device for making the container includes a male mold including a main body, a bottom forming portion received in the main body for vertical movement relative to the main body and a pressurizing portion disposed for vertical movement relative to the bottom forming portion and a female mold for receiving a portion of the bottom forming portion. The method of making the container includes the steps of forcing a portion of the bottom forcing portion into the female mold to form the bottom of the container, raising the bottom forming portion and substantially simultaneously moving the pressurizing portion to form the rim or legs on the bottom of the container.

Abstract: A molded product having a printed circuit board on a thermoplastic layer is disclosed, the printed circuit board comprising a conductive metal layer and a thin-wall body containing a crosslinked product of a mixture of (A) 1 to 99 wt % of an ethylenic copolymer containing at least one monomer unit selected from the group consisting of monocarboxylic acid unit, dicarboxylic acid unit, acid anhydride unit thereof and half ester unit thereof and (B) 99 to 1 wt % of an ethylenic copolymer containing at least one monomer unit selected from the group consisting of hydroxyl unit, amino unit and oxirane unit.

Abstract: Fiber reinforced molding compounds wherein the resinous matrix is a thermosetting linear polymer characterized in constituting two oligomeric ethylenically unsaturated polyester segments joined through a polyurethane residue and having acryloyl or methacryloyl end groups.

Abstract: A flowable particulate polymer-metal mixture that is thermally conductive and is particularly adapted for use as a pressurizing medium in a high pressure elevated temperature molding process. The material comprises a substantially uniform mixture of about 20% to about 90% solid flowable, particulate silicone rubber having a nominal flow rate of at least 0.6 gram/second through a 1.1 cm diameter pipe 7.6 cm long under applied pressure of 10.34 MPa at room temperature. The material also comprises about 10% to about 80% thermally conductive particulate metal that has a melting point less than the molding temperature and is substantially chemically compatible with said silicone rubber. The pressurizing medium is used to mold article precursors into articles by placing an article precursor within a pressure vessel and substantially filling the vessel with a pressurizing mixture.

Abstract: There is provided a method of manufacturing a ceramic, wherein a ceramic material is covered with a foil of a metal selected from the group consisting of molybdenum, tungsten, platinum, and rhenium, sealed into an airtight vessel of tantalum or niobium, and then subjected to a hot isostatic press process. The method of the present invention can suppress coloration produced in the hot isostatic press.

Abstract: A system for molding elongated ribbon-like products from thermoplastic materials utilizing a plurality of molds which are moved in tandem along a production line. As the molds are moved along the line at successive stations they are, while open, thermally adjusted to a temperature suitable for forming the product to be molded and then a ribbon of plastic is deposited in them. They are then closed and cooled and reopened and the molded product removed. The system utilizes only enough molding pressure to assure distribution of the plastic to all parts of the mold cavity and shaping of the molded product to the geometric design of the mold. The system includes a transfer means for the molds which returns the emptied molds for recycling through the molding process.

Abstract: The invention relates to a high molecular weight polyolefin part, particularly for an articular prosthesis and to its production process by shaping in a closed mould. This part, which has a friction surface, has a structure such that the polyolefin chains are oriented parallel to the friction surface, at least in the zone of the part located below or flush with said friction surface. This orientation is obtained during the shaping of the blank of the part in a closed mould having a metal belt, a hemispherical block and a mobile punch, as a result of the choice of shaping conditions, particularly the shaping temperature and the length/transverse dimension ratio of the blank.

Abstract: A method of producing a continuous fiber reinforced bent resin pipe, including winding a continuous reinforcing fiber on the outer surface of a tube-like flexible core mold while such core mold is straight in shape, the flexible core mold which is straight when unloaded being capable of keeping a cross section defined in radial direction when the core mold is bent. The core mold on which the continuous fiber has been wound is then bent and placed into a cavity defined by an outer mold formed of split molds each having an inner surface forming the predetermined outer configuration of a bent pipe. A liquefied synthetic resin is caused to be cured between the outer and the core molds to integrate both the fiber and resin. Thereafter the molded product is removed from the outer mold and the core mold is removed from the molded product.

Abstract: In production of a composite type iron golf club head having a FRP (fiber reinforced plastic) backing in a rear recess, a peripheral flange to be caught by the main body is formed on the FRP backing by providing a bottom peripheral groove in the rear recess for fortified bonding of the FRP backing to the main body.

Abstract: A process and apparatus for molding a plurality of articles of hardenable material such as plastic which requires each article to be maintained under heat and pressure for a cure interval. A molding press is utilized wherein there is placed a first open mold assembly having spaced die halves between supporting mold platens. At least one of the die halves has a resilient pressure pad between the die and the mold platen supporting the die half. The press is closed to maintain the mold platens in a first force applying position having a slight gap between the die halves and locking the platens in the first position. The mold assembly is removed while in its first locked position from the press and gas from the curing material is evacuated through the gap between the die halves while heating the material.

Abstract: The tubular body is laid in a horizontal position on a tapered suction drum and pivoted thereby into a vertical axis which is in coaxial relationship with the axis of a mandrel with a punch. The tubular body is then pushed from the surface of the suction drum on to the mandrel by a thrust member. The mandrel and/or the die is mounted displaceably in a vertical direction, which permits particularly stable and precise guidance. A plurality of dies with mandrels and punches associated therewith is disposed on a rotary member. In the course of a revolution of the rotary member, the tubular body on the mandrel is connected to a squeeze moulding in the die.

Abstract: A method for production of a shaped body having high mechanical strength, high modulus of elasticity, and good mold-releasing property, the method comprising steps of charging a metal salt of polyacrylic acid in powder form into a shaping mold; and press-forming the powder material into a shaped body under a pressure in a range of from 100 kg/cm.sup.2 to 1,000,000 kg/cm.sup.2.

Abstract: The invention relates to producing relatively flaw free silicon nitride ceramic shapes requiring little or no machining by superplastic forgingThis invention herein was made in part under Department of Energy Grant DE-AC01-84ER80167, creating certain rights in the United States Government. The invention was also made in part under New York State Science and Technology Grant SB1R 1985-10.