Abstract: A method is disclosed of reshaping a sheet of resiliently deformable material impervious to fluid by conforming it to the cavity of a female mold and casting a flexible plastic foam into contact with said sheet material, whereby said material is integrated with the foam and forms a cover sheet therefor. A perforated elastic diaphragm is interposed, during the reshaping and foam casting process, between the cover sheet and surface of the mold cavity so that the cover sheet is in superimposed direct contact with the diaphragm throughout its area. The two are clamped to the periphery of the mold to form a seal thereat, and a differential pressure is applied across the cover sheet and diaphragm. The sheet is therefore deformed against the walls of the mold simultaneously with the diaphragm and is stretched evenly with the diaphragm in order to produce uniform thickness.

Abstract: Shaped articles of hydraulic cement compositions reinforced with fiber glass fabric or with chopped fiber glass, and having a smooth, reflective surface, are produced by the admixture of "super" water reducers to the aqueous cementitious slurries followed by casting or spraying into synthetic polymer molds, or molds coated with such synthetic polymers which are water repellent and non-sticking to hydraulic cements, to yield cured articles of high flexural strength with at least one surface which is an exact reproduction of the surface of the synthetic polymer mold, such as high gloss and patterned design. A great variety of useful articles may be produced, such as building panels, curtain walls, hollow utility poles and pipes, "raised" flooring panels, roofing tiles, protective barriers, and other products requiring thin shell, high flexural strength products for decorative and utilitarian uses.

Abstract: A method is provided to make substantially flat-topped blocks of plastics foam, e.g. polyurethane, by a batch process. The foam-forming reaction mixture is dispensed into a cavity defined by a support and shaping members for the sides of the block. As the foaming commences the support is lowered so that the zone of contact between the shaping members and the foam remains constant. By this means the dome-shaped effect of free-foaming is avoided.

Abstract: Method of making slabs of building material which can be used in place of slabs of compact marble are prepared by lining at least one surface of a mold with bonding material, introducing into the mold pieces of solid material to form an aggregate of individual pieces of said solid material with interstices therebetween, filling these interstices with bonding material which chemically bonds to the bonding material utilized for lining, allowing the bonding material to cure and harden to form a solid block of lined material, removing the solid block of lined material from the mold and slicing said block to desired size.

Abstract: The invention relates to a thermoplastic moulding composition comprising an aromatic high-molecular weight polycarbonate based on a diphenol, with a weight-average molecular weight (M.sub.w) of at least 10,000 and from 0.5 to 5% by weight, relative to the high molecular weight polycarbonate, of a polycarbonate which has an M.sub.w of from 1,200 to 9,000 and which corresponds to the formula (I): ##STR1## wherein "E" represents a radical of the formula (II): ##STR2## in which THE GROUPS R' are identical and denote H or halogenx is an integer of from 7 to 24"Z" is a divalent aromatic radical, and"n", the degree of polymerization, results from the M.sub.w between 1,200 and 9,000.

Abstract: A horizontal brick feed conveyor continuously feeds green undried moist clay bricks along a path beneath a lower horizontal flight of an elastic hold-down belt member mounted above and moving in the same direction as the conveyor to engage the upper surface of the conveyed brick; a relatively large motor-driven irregularly spaced impression roller is adjustably mounted adjacent the upper surface of the horizontal flight of the hold-down belt to engage the horizontal flight so that a number of protrusions on the roller deflect portions of the elastic hold-down belt downwardly into the green brick immediately beneath the hold-down belt so that the bricks are distorted and misshaped to give an antique or handmade effect.

Abstract: A composition particularly effective as a high temperature lubricant for molds used in glass-forming operations and effective at high temperatures of the order of about 1,000.degree. F, comprising a mixture of graphite and a high melting inorganic oxide or salt, preferably potassium titanate, and an inorganic binder e.g. a slurry of magnesium oxide in a mixture of phosphoric acid and chromic acid. The mold lubricant composition also preferably contains a wetting agent, e.g. butyl Cellosolve (ethylene glycol monobutyl ether).

Abstract: Two mold halves together form a mold cavity and one of the mold halves is fitted with a plurality of ejector rods that can be reciprocated so as to push a molded article out of that half. At least some of these ejector rods are formed with throughgoing passages terminating adjacent the inner ends thereof at nozzle openings. Air and a treatment fluid, such as a demolding liquid, can be injected into the mold interior through these rods, the nozzle openings in the ends of the rods being covered during the normal molding operation.

Abstract: A process for metal plating shaped articles, such as cast or molded articles of synthetic resins, includes the steps of (a) diffusing or scattering numerous fine metal particles (or pieces) over the surface and outermost layer of the articles, (b) etching exposed surfaces of the metal particles, (c) performing thereafter metal plating, (d) and thereby solidly combining or joining the plating layer and the articles through the medium of the fine metal particles, whereby the resulting plated articles are extremely eminent in abrasion and shock resistance which is essentially useful for casting and molding patterns or core boxes.

Abstract: Method of producing a three-dimensional pattern on a resin article which comprises producing a two-dimensional pattern on a flexible sheet or web of a heat-foamable plastic material, applying heat to cause said plastic material to expand, thus forming a three-dimensional pattern, applying a release coating to the three dimensional surface of said flexible sheet or web, contacting said three-dimensional surface with a resin plastisol, curing said resin plastisol in contact with said surface to form a solid resin object and removing said flexible sheet or web from said cured resin object to expose the three-dimensional pattern thereon.

Abstract: There is disclosed an article useful for producing concrete with textured patterns which includes a membrane of water permeable material having a pattern prepared on one side thereof with a water soluble retardant for the setting of cement and with the retardant pattern completely covered with a waterproof film that is bonded to the membrane immediately adjacent the retardant pattern. There is also disclosed a method for preparing concrete to have a pattern on its surface employing the article.

Abstract: A contact lens composition, having improved dimensional stability, suitable for use in the preparation of a corrective hydrated lens or an eye bandage, comprises polymerized random graft copolymers containing (in the dry state) from 67.2% to 79.3% HEMA; from 14.25% to 35% PVP; from 0.1% to 4.04% EDMA; from 0.1% to 2.5% MA; from 0.1% to 5.0% water; from 0 to 4 ppm HQ inhibitor; and from 50 to 250 ppm MEHQ inhibitor. The contact lens composition contains from 45% to 65% water after hydration. An improved method for shaping, polymerizing, and cutting and hydrating the contact lens composition is provided. The polymerization is conducted using only a low temperature initiator, by de-gassing prior to polymerization to remove substantially all oxygen, and by conducting the initial polymerization reaction at from 23.degree. C to 30.degree. C for 16 to 30 hours, during which the heat of the reaction is continuously absorbed to control the reaction exotherm.

Abstract: A connector for light-conductive fibers includes a connecting body provided with at least one receiving passage and at least two aligning passages. The connecting body is subdivided into two connecting members along a plane normal to the axes of the passages, the connecting members having contact surfaces at the subdividing plane which are adapted to abut one another when the two connecting members are assembled. The end portions of the light-conducting fibers are introduced into the receiving passages so that the end faces thereof are flush with the contact surfaces, and the connecting members are assembled in alignment with one another, using aligning elements accommodated in the aligning passages of the connecting members. The connecting body may be produced by embedding auxiliary elements corresponding in diameters to the aligning elements and the fibers, in a body of a hardenable material, and by removing the auxiliary elements from the body after the hardening of the material.

Abstract: A method for densifying to near theoretical density a shaped body of compacted powdered particles, particularly of a refractory material, by preforming a shaped body of compacted particles of a powdered material characterized by voids, enclosing the shaped body within a loose mass of a pressure-transmitting powder disposed within a confining mold, applying a unidirectional pressure to the pressure-transmitting powder within the mold in order to compress the shaped body more compactly while heating the body to at least the densification temperature of the body, preferably in a controlled atmosphere, the temperature and/or pressure being increased incrementally up to the densification temperature of the refractory material, whereby substantially all voids within the compacted shaped body are collapsed.

Abstract: A mold release agent comprising metallic soaps of the fatty acids in combination with 0.03 to one percent of a polyurethane catalyst selected from secondary and tertiary amines and organic tin compounds.

Abstract: Shaped articles such as tiles and panels are produced from aqueous slurries of hydraulic cement, with or without aggregate, to which "super" water reducers have been admixed, by casting in a synthetic polymer mold with glossy, water-repellent surface, to yield castings with highly reflective, glassy surfaces. Color pigments may be added to the formulation to yield castings with reflective, glossy colored surfaces.

Abstract: A mold release agent for foamed rubber formulated from the sodium soap of tall oil acids, kerosene and paraffin wax has improved mold release properties. This mold release agent is effectively removed from the molded articles by water washing, thus eliminating the need of hydrocarbon solvents. A preferred method of manufacture of the mold release agent is also described combining the tall oil and a paraffin base oil and heating to 125.degree. F., neutralizing with aqueous alkaline solution dehydrating and heating to 315.degree. F., adding 25% more paraffin base, cooling while stirring, adding wax at 245.degree. F. and finally adding kerosene when mixture has cooled to 130.degree. F., to provide an improved mold release agent.

Abstract: A form molded synthetic foam roofing section having a relatively broad undersurface and an exposed surface configured to resemble interlocked and overlapping roofing shingles which is united to a support surface such as wood, metal, etc. during molding process. This section may be affixed by any conventional means such as nails and adhesives to roof boards, rafters or over old existing roofing structure.

Abstract: An improved molding apparatus is described for use with relatively light weight molds, particularly molds for articles having a plurality of voids therein. A light weight two-piece mold, one-half being substantially rigid and the other relatively flexible, is disposed in a jig. The two halves of the mold are held in sealing relationship by inserting a hollow inflatable bag between the exterior of the relatively flexible mold piece and the interior wall of the adjacent jig member and inflating said bag to a pressure superior to that exerted by the expanding foam mix in the mold.The use of the improved apparatus obviates the need for molds of high structural strength (and hence excessive weight) and gives molded articles, particularly those of complex configuration, which are free from flashing.

Abstract: Plastic articles without foam spots are produced by an improved powder forming process wherein a powder of normally solid, thermoplastic polymer is compacted by means of vibratory energy into briquettes which are subsequently forged and formed into articles of fused polymer.

Abstract: A load-bearing wall panel is fabricated by disposing an assembly of spaced-apart and aligned, hollow-cored bricks onto a molding base containing melted paraffin. Contact of the cooler bricks with the melted paraffin forms a thin skin of solidified paraffin on the brick bottom portions and forces melted paraffin within the joints forming therein a double-convex configuration of solidified paraffin, thereby water-proof sealing the brick bottom portions and joints preparatory to mortar introduction. After curing of the mortar introduced in the joints and cores, the resulting wall panel has load-bearing capacity and unique, double-concave mortar joints that are smooth, water-proof and weather-proof.

Abstract: Shaped articles such as tiles and panels are produced from calcium aluminate cement motars by casting in a mold with a glossy water-repellent synthetic polymer surface to yield castings with highly reflective glassy surfaces. The calcium aluminate layer need only be several mils thick with the rest of the mold volume being filled with other cementitious compositions. Color pigments may be added to the calcium aluminate slurry to yield castings with brilliant glassy colored surfaces.

Abstract: A polyurethane reaction mixture mold release comprising 1 to 5 percent by weight of a sodium or potassium soap of a carboxylic acid of 11 to 22 carbons in a diluent of alcohol or water, the mold release being applied to a mold, then addition of a polyurethane reaction mixture to form a shaped polyurethane of the microcellular type, stripping the shaped article from the mold, flushing with water at 40.degree. to 95.degree.C., drying, applying a paint coat of 3 to 10 mils over the polyurethane article to obtain a polyurethane decorative article having a paint coat resistant to peeling.

Abstract: An improvement in a process for producing a synthetic resin cast article having an abrasion-resistant polymer surface layer integrated with the polymer body is provided. The improvement is characterized in that the abrasion-resistant polymer surface layer is formed by a two step polymerization procedure; in the first polymerization step, the polymerizable material is covered with a covering body such as a polymer film, closely adhered thereto, and in the second polymerization step, the polymerizable material is exposed to the air.

Abstract: Box-like units having at least one open side for use, for example, in the construction of prefabricated buildings are cast from a composition of gypsum and water optionally including other material such as Portland or Aluminous cement. The mixture is cast between an external mould defining the external faces of the unit and an internal core defining the internal faces of the unit and the core is formed from, or covered with, material which causes its faces which come into contact with the mixture to have a higher co-efficient of heat reflection than that of the faces of the external mould which come into contact with the mixture. The mixture is allowed to set and the external mould is removed, after which the mixture is allowed to harden further and during this hardening becomes heated by the exothermic reaction between the gypsum and the water to cause the hardened mixture to expand away from the core. This allows the core to be subsequently removed without it being necessary to make the core collapsible.

Abstract: A mold section is made by covering at least the surface of a cavity of a metallic substrate with a layer of plastic barrier material. A pattern is then placed on this so-covered surface. A compressive force and heat are applied to the metallic substrate and pattern causing the material of the layer to flow and then become bonded to the surface of the cavity while duplicating the surface and shape of the pattern.

Abstract: A method of producing a moulded article from concrete or the like comprising; having at least a portion of a mould formed of expanded polystyrene; treating the moulding face of the expanded polystyrene to form a textured and/or patterned surface; applying a colored composition to the moulding face of the expanded polystyrene; filling the mould with concrete or the like; upon the solidification of the concrete or the like, applying an organic solvent to the expanded polystyrene, wherein a portion of the solution of the solvent and polystyrene is caused to remain on the moulded article, the amount of solution remaining upon the moulded article being controlled by the amount of solvent applied to the expanded polystyrene; permitting the solvent to evaporate from the solution remaining on the moulded article to form a colored glazed finish upon the moulded product.

Abstract: A fiber reinforced composite tube is molded by applying an annular, liquid-resin-impregnated layer of reinforcing fibers to a cylindrical mold or mandrel; placing in contact with the exposed surface of the fiber-resin layer a compression sleeve which is split lengthwise to permit circumferential contraction or expansion of the sleeve into pressurizing relation with the layer; pressurizing the compression sleeve with fluid pressure to compress the fiber-resin layer and thereby compact the reinforcing fibers and expell entrapped air and excess resin from the layer; and curing the resin while the fiber-resin layer is so compressed.

Abstract: Method for making elongated structures such as furnace tubes having at least one flat side from vapor deposited silicon or silicon carbide using a graphite mandrel having a plurality of elongated edge-mated elements held in place by end collars to which an electrical power source is connected. Rectangular tubes can be sawed apart to produce flat plates if desired.

Abstract: A substrate to be used as a support for a release coating is provided with a powdery release support with a release agent which is substantially non-tacky by applying on the support an aqueous solution, dispersion or paste containing a lactam compound which is water soluble, swells in water or forms a paste with water, drying the resulting coating. The process comprises treating the release agent, drying the release agent, applying a polyurethane coating over the release support and then removing the polyurethane coating from the release support. The release agent is selected from lactams and addition compounds of lactams with water, oximes, amines, monofunctional or polyfunctional alcohol or thioalcohols and mixture thereof.

Abstract: The invention involves the use of aluminum salts of a fatty acid mixture of fatty acids having 12 to 22 carbon atoms consisting ofA. from 42% to 50% by weight of mono-olefinically unsaturated fatty acids, wherein at least 42% by weight are oleic acid,B. from 42% to 48% by weight of saturated fatty acids, wherein at least 42% by weight are saturated fatty acids having 16 to 18 carbon atoms, andC. from 2% to 10% by weight of poly-olefinically unsaturated fatty acids,As a mold releasing agent for the release of polyurethane foams from molds.

Abstract: A process for artificially forming rocks is described. The process provides for forming a rubber film mold of the surface of a natural rock. The rubber film mold is then placed on a bed of flowable supporting elements which are distributed to support the underside of the cavity of the rubber film mold such that it assumes a desired contour or shape. A filling of concrete poured into the cavity of the mold upon hardening and being turned over provides an artificial rock whose surface has the characteristic markings of the natural rock but may have any desired different overall contour or shape.

Abstract: The provision of a durable, slick sliding surface on metal faces of plastic forming extrusion apparatus such as extruder nozzles and dies. The durable, slick sliding metal surface is provided by burnishing and heat treating a polysiloxane fluid on the face of the metal. The burnishing comprises vigorous rubbing of the polysiloxane fluid treated metal face with a material relatively softer than the metal face being treated, effectively over the entire surface treated.

Abstract: This invention relates to the use of salts of diamines having the formula ##EQU1## where R.sub.3 is alkylene having 2 to 4 carbon atoms and R.sub.1 and R.sub.2, together or separately, are hydrogen or alkyl having 1 to 8 carbon atoms, with an anion component having the formulaR--X.sup.-where X.sup.- is --SO.sub.3 .sup.- or --OCO.sub.3 .sup.- and R is a hydrocarbon radical having 6 to 26 carbon atoms which may be interrupted or substituted by groups containing heteroatoms, as parting agents for natural and synthetic elastomer compositions.

Abstract: A method for hot isostatically compacting powder metallurgy charges in sealed metal containers wherein the container may be easily removed from the charge after compacting by providing a separating medium between the container interior and the powder metallurgy charge to prevent bonding during subsequent hot isostatic compacting, and producing during hot isostatic compacting a residual stress in said container; slitting of the container after compacting releases the residual stresses and in the absence of bonding to the compact causes the container to move away from the compact, thereby avoiding typical container-removal operations such as machining and pickling.

Abstract: Thermosetting molds are formed with electrically conductive surfaces for use in high frequency energy flow molding of sheet materials. Preferably the mold of this invention has a highly electrically conductive layer preferably in an epoxy gel coat carrying electrically conductive particles of gold, silver or platinum and positioned over a compatible epoxy mold body. A vacuum molding technique is used to obtain good surface definition in surface molding.

Abstract: A process for producing cast polymer is carried out by using a mold treated by the following steps: coating the glass surface of the mold with polysiloxane; heating the coated glass surface at a temperature in the range of from more than about 150.degree. C. to a temperature at which the coated polysiloxane is not hardened yet; and wiping the coated surface of baked polysiloxane. Not only is easy mold release attained, but also repeated use of the same mold becomes possible.

Abstract: A method of molding polyurethane articles using three mold release agents, the first being a halocarbon film, the second a hydrocarbon release agent and the third a polyvinyl alcohol release agent.

Abstract: In molding polyurethane integral-skin foam the foam tends to stick to the mold surface. Conventional mold release agents have not been found effective; they fail to provide full release of the molded product, are not durable enough to withstand more than one molding cycle, interfere with development of the integral skin, or plate onto the integral-skin thus necessitating solvent washing of the molded foam product. This invention is a method of preparing a mold to release flexible polyurethane integral-skin foam, free from skin damage and other defects, that is durable, i.e., that will permit many molding cycles before requiring replacement, and that permits the molded foam to be merely water washed to remove all traces of the mold release agent.

Abstract: A mold for forming plastic foam parts in which an injection-molded plastic member forms a molding surface of the foam molding cavity against which foam plastic is adapted to be molded. The plastic member is preferably injection molded in a metal molding die from either polyethylene or polypropylene so that its molding surface is the reverse of the exterior surface of the plastic part to be foam molded therein. Vent passages and sealing beads may be integrally formed with the injection-molded member.