Abstract: A method is provided for manufacturing molded simulated stone and wood architectural articles for buildings and homes. The method incorporates a unique mold assembly including a resilient silicone rubber mold supported within a rigid mold cradle/foundation, and a vented lid having a High-Density Polyethylene (HDPE) interior surface. The silicone rubber mold is initially treated with a liquid polyester gel coating that is cured and then coated with an acrylic/vinyl ester back coating. Once the back coating is cured, a predetermined volume of a modified high-density, natural mineral fiber-reinforced, 2-component hybrid polyurethane liquid expanding composition is dispensed therein and the mold is covered with the vented lid. The system is pressurized and heated to produce a molecularly-fused, lightweight rigid article having the desired architectural shape.

Abstract: A method of manufacturing an optical disk includes spin-coating a substrate with a resin to form a light transmission layer without an additional cover. A spindle jig, which has a central shaft and is formed of a non-adhesive substance, is prepared. A resin is discharged on a surface of the spindle jig. The substrate is placed on the resin so that a recording layer of the substrate faces the spindle jig, and the substrate is spun to form the light transmission layer from the resin. The substrate, which is coated with the light transmission layer, is separated from the spindle jig. Accordingly, the resin is discharged not on a center of the substrate but around the center of the substrate. Thus, the additional cover is unnecessary, and thus a process of manufacturing the optical disk is simplified. Also, an entire surface of the substrate can be uniformly coated with the light transmission layer using the spindle jig and/or a dummy substrate formed of non-adhesive substances.

Abstract: Described are molds, dies and forming tools comprising: a) a heat exchanging body support member; and b) within the support member, a molding cavity portion formed by thermal spraying metallic particles to a desired configuration in the support member. Also described are methods of making a mold, die or forming tool comprising the steps of: a) providing a body support member having a controlled and designed porosity which permits the enhancement of the heat transfer ability of said mold, die or forming tool; b) configuring a surface of the support member to a desired cavity; and c) spraying particles to the configured cavity in the support member, thereby producing a mold, die or forming tool. Preferably, the materials of construction are metallic and are applied by thermal plasma spraying. The particles may also be ceramics, metal matrix composites, ceramic matrix composites, thermoplastic resins, thermoset resins, and composites based thereupon.

Abstract: Apparatus and method for forming a molding trim, such as a simulated coiled rope, including forming a mold having raised and depressed areas and placing an uncured material into the mold thereby forming raised and depressed areas in the material simulating a coiled rope or the like.

Abstract: A method of making precision geometry honeycomb material formed of a composite material and exhibiting dimensional uniformity, is disclosed. Composite material is molded in the cavity of a single-sided female mold to form a first web with a plurality of honeycomb cell portions of the desired cell shape in the web. The details of the cavity mold configuration are captured to form the honeycomb cell portions in the composite material during molding the web by applying pressure to the composite material in the mold with an elastomeric pressure intensifier. The composite material of the web is stabilized as by curing. First and second molded webs are precisely aligned in a fixture and joined together at facing cell nodes thereof by bonding yielding a honeycomb material with superior geometric platform.

Abstract: A process for manufacturing a capital for an architectural column. The inside of a mold for an architectural column is lightly coated with a mold release. A first opening of the mold is placed upon a surface, and a plug is positioned on the surface within the first opening. Through another opening foam is poured around the plug. After the foam has hardened, the mold is removed from the surface. All other openings in the mold are securely covered. Then an elastomer is introduced into the mold, and the mold is rotated about three different axes. The introduction of the elastomer is repeated after the prior coating created by the introduced elastomer has become tacky but before the prior coating has become firm. After the final coating of elastomer has become tacky but not firm, foam is introduced into the mold.

Abstract: Disclosed is an injection molding method. The method comprises injecting a melt of thermoplastic material at a temperature higher than the glass transition temperature (Tg) of the thermoplastic material in a molding cavity defined by a two-piece mold insert. The article is recovered after cooling and disassembling of the two piece mold insert. Each of the two pieces of the mold insert comprise at least one portion partly defining the mold cavity which is made of a material or combination of materials, other than glass, the thermal diffusivity &agr; of which fulfills the condition: 1<&agr;/&agr;g<11, wherein &agr;g is the thermal diffusivity of a borosilicate glass and is equal to 6.20×10−7 m2 s−1. The portion is at least 1 mm thick. The injection molding method can be used to form weld free minus lenses.

Abstract: The addition of thin coatings (less than and approaching monomolecular coatings) of persistent release materials comprising preferred compounds of the formula:

Abstract: The invention provides non-stick coated molds, a process for the preparation thereof and their use for the production of plastics molded parts, particularly for the production of molded parts made of polyurethane foam.

Abstract: The addition of thin coatings (less than and approaching monomolecular coatings) of persistent release materials comprising preferred compounds of the formula:

Abstract: A FRP plate member fabrication method includes the steps of: (a) form preparation to prepare a form having a cavity made subject to predetermined dimensions and pattern, (b) coating and hardening to coat the cavity with a layer of mold releasing agent and a layer of face material on the layer of mold releasing agent and then to harden the layer of face material, (c) FRP layer formation to coat a layer of FRP on the layer of face material and then to harden the coating, (d) resin coating to coat a layer of resin on the layer of FRP, (e) sheet member adding to bond a backing sheet to the layer of resin, (f) pressure application and mass production to compress backing sheet against the form and then to repeat the steps from (a) through (e) for making multiple FRP plate members at a time, and (g) form releasing to release the molded and hardened FRP plate members from the form.

Abstract: The Aluminium mould for forming Urethane resin and the method for manufacturing Urethane resin has high durability and releasability. The mould surface is coated by Nickel containing PTFE and the said mould is used for Urethane resin manufacturing process.

Abstract: Hydrophobic polymer surfaces whose level of protein binding is less than about 50-80 ng/cm2 are achieved by: (1) applying a coating solution composed of a solvent and a non-ionic surfactant having a HLB number of less than 5 to the surface; and (2) drying the surface to remove the solvent and thereby bring the surfactant into direct contact with the hydrophobic polymer. The combination of a low HLB number and the drying step have been found to produce low binding surfaces which can withstand multiple washes with water and/or protein-containing solutions Alternatively, the low binding surfaces can be produced by applying the non-ionic surfactant to the mold surfaces which contact molten polymer and form the polymer into a desired shape, e.g., into a multi-well plate, a pipette tip, or the like. Further, the low binding surfaces may be produced by incorporating non-soluble, non-ionic surfactants having an HLB number of less than or equal to 10 into a polymer blend prior to molding the article.

Abstract: Surface modifications of a mold used during semiconductor device fabrication provide non-stick characteristics and a mold surface that is resistant to abrasion or wear. Such surface modifications are particularly useful in a mold having a quartz planar surface adapted to contact a photocurable polymer material applied to a semiconductor wafer surface during a fabrication process. The planar surface of the mold is capable of allowing transmission of ultraviolet light therethrough to cure the polymer material. A non-stick film is formed on the planar surface of the mold by a coating or deposition process in order to modify the mold surface. The non-stick film can be formed of a fluoroalkylsilane compound. or a hard material such as diamond or diamond-like carbon. The non-stick film of diamond or diamond-like carbon provides protection against abrasion or wear on the planar surface of the mold.

Abstract: A panel structure mountable in a vehicle to form a part of the interior thereof, and a process for making the same. According to this process, an outer layer defining at least a portion of the exposed exterior surface of the structure is prepared by applying a water-dispersed thermoplastic polyurethane composition and a light-stable, blocked, heat-activated diisocyanate onto a mold surface and thereafter drying the composition. Next, a rapidly reacting composition is sprayed onto an inner surface of the outer layer while the outer layer is retained on the mold surface to form a polyurethane elastomer inner layer that is interfacially chemical bonded to the outer layer. The inner layer with the outer layer interfacially chemically bonded thereto is then united with the reinforcing substrate so that the reinforcing substrate serves to reinforce the outer layer.

Abstract: A device for stamping a detergent bar, i.e. a bar comprising soap, a synthetic detergent active or a mixture thereof, includes a die. The die has at least one bar stamping surface provided with at least one elastomeric coating which includes a conductive filler such as stainless steel powder. Good release of the detergent bars from the die is possible particularly when the dies are chilled. Use of the conductive filler facilitates chilling of the dies.

Abstract: A release composition for facilitating removal of shaped articles from a shaping surface. In one embodiment the release composition includes a water-soluble, no-cure dimethicone copolyol. The dimethicone copolyol may include polyoxyethylene and/or polyoxypropylene side chains. The composition is coated on a mold or mandrel surface and or the article and the article and surface is heated to shape the article. The composition prevents the article from adhering to the surface during heating, and thus prevents damage to the when the article is removed from the surface. Because the composition is water-soluble, it is easily washed from the article with water.

Abstract: A method of forming a cannula by forming a cannula mandrel assembly having a nare mandrel, a main body mandrel and mouthpiece mandrel; heating the cannula mandrel assembly, applying a polymeric material to the cannula mandrel assembly to provide a desired material thickness on the mandrel assembly to form the cannula, curing the polymeric material of the formed cannula and extracting the mandrel assembly from the cannula by disassembly and removal of the mandrel assembly parts.

Abstract: A method for molding an optical disk comprises: applying a thermally insulative insert coating to at least one thermally insulative mold insert to provide at least one coated mold insert having a reduced surface roughness; positioning the coated mold insert between a thermally conductive mold form and a portion of a thermally conductive mold apparatus; injecting a molten thermoplastic material into the mold apparatus; retaining the material in the mold apparatus for a time sufficient for the molten thermoplastic material to cool below its glass transition temperature to form the optical disk; and ejecting the optical disk from the mold apparatus. In another embodiment, the mold insert is coated or laminated on the mold form with the mold insert having a coefficient of thermal expansion compatible with the coefficient of thermal expansion of the mold form. In another embodiment, the mold insert is fabricated by being applied, cured, and then removed from a release layer.

Abstract: A method of forming a cannula by forming a cannula mandrel assembly having a nare mandrel, a main body mandrel and mouthpiece mandrel; heating the cannula mandrel assembly, applying a polymeric material to the cannula mandrel assembly to provide a desired material thickness on the mandrel assembly to form the cannula, curing the polymeric material of the formed cannula and extracting the mandrel assembly from the cannula by disassembly and removal of the mandrel assembly parts.

Abstract: A method of making a polyurea-polyurethane composite structure that is substantially free from emission of volatile organic compounds is disclosed. The composite structure produced according to the method of the subject invention has a flexural modulus of at least 200,000 lb/in2. The composite structure includes first and second layers. A mold substrate is provided and a first-layer polyisocyanate component and a first-layer resin component are reacted and sprayed onto the mold substrate to form the first-layer. The first-layer polyisocyanate component includes an aliphatic polyisocyanate, and the first-layer resin component includes a polyamine thereby forming a polyurea show surface having a Shore D hardness of at least 65. After application of the first-layer, a second-layer polyisocyanate component and a second-layer resin component are reacted and sprayed behind the first-layer to form the second-layer of the composite structure.

Abstract: A method of forming ablative insulation coatings on aerospace structures and articles produced thereby. The method includes forming a mold having a cavity configured to complementarily receive at least a portion of the structure and directly molding the ablative coating to a surface of the structure by introducing a prepared ablative mixture, such as an epoxy resin, into the mold. The process may desirably include curing at atmospheric pressures to reduce the expense and equipment required in carrying out the process. The method of applying the ablative coating further includes features such as varying the thickness of the ablative coating from one portion of the component to another. Control of the thickness may be effected through use of spacers embedded into the ablative coating an formed of the same or similar material previously cured prior to placement in the mold.

Abstract: The addition of thin coatings (less than and approaching monomolecular coatings) of persistent release materials comprising preferred compounds of the formula:

Abstract: A method and a system for fabricating articles made from thermoset resins using an ionic mold release agent. The invention uses a mold having a metal oxide surface with enhanced mold release characteristics. The release agent is applied internally in the resin composition or externally on the metal oxide surface. The method includes providing a mold, forming a metal oxide surface on the mold, providing an ionic release agent, providing the acid or base conjugate of the release agent at the metal oxide surface, providing a thermoset resin in the mold, and curing the resin in the mold. A method of using float glass having a SnO2 enriched surface, wherein the method includes the steps of providing an ionic release agent externally to the tin oxide surface, is also disclosed.

Abstract: Methods and devices for manufacturing a conduit for placing a target vessel in fluid communication with a source of blood, such as a heart chamber containing blood. The conduit includes first and second portion adapted to be placed in fluid communication with a heart chamber and a target vessel. The conduit lies on the exterior of the myocardium between the blood source and the target vessel and delivers blood in multiple directions within the lumen of the target vessel. The conduit, which may be formed of any suitable synthetic vascular graft material, is generally T-shaped with the leg having two free ends disposed in the target vessel, preferably being secured thereto via a suture-free attachment. The conduit comprises vascular graft material and may be manufactured various ways, such as molding a conduit from any suitable biocompatible material or fabricating a conduit from one or more pieces of vascular graft material.

Abstract: A molding method and a molding die for producing a lens of a vehicular lamp wherein the lens has an improved appearance in that no weld lines are formed on the surface of the lens and the lens consequently has an improved mechanical strength. The molding die has a gathering area for molten resin in the molding cavity in a flow region of the molten resin to be formed into a lens. A heat insulating layer is formed on a cavity face on the side of the lens surface at the gathering area for the molten resin in the molding die, as a result of which instantaneous cooling is prevented. Accordingly, a skin layer formed on the side of the lens surface at the gathering area is very thin, thereby preventing the generation of a weld line, which could otherwise be generated if thick skin layers produced when high-temperature molten resin directly comes into contact with steel material and cooled instantaneously are gathered together.

Abstract: A method of manufacturing a headliner assembly for use in the interior compartment of an automotive vehicle comprising the steps of: placing a mold release film onto a concave mold surface of a lower mold assembly for providing a barrier against the mold surface; placing a fiber mat on the mold release film; applying a foamable material directly onto the fiber mat; expanding the foamable material around the fiber mat to embed the fiber mat therein; placing an adhesive film onto a convex mold surface of an upper mold assembly; positioning the lower mold assembly directly beneath the upper mold assembly; moving the upper mold assembly in mating engagement with the lower mold assembly to define a mold cavity between the convex mold surface and concave mold surface; curing the foamable material within the mold cavity; and bonding the mold release film and adhesive film to the foamable material with the fiber mat embedded therebetween.

Abstract: A releasing agent for embossing a thin film carried on a surface of a substrate with a mold having a high pattern density includes an alkyl silane.

Abstract: A molding die having satisfactory releasability, a sol-gel composition produced using the molding die, and a process for producing a sol-gel composition. The molding die which is to be pressed against a sol-gel material for producing a sol-gel composition has a release film, e g., a thin gold (Au) film, formed on the molding surface of the molding die through a buffer layer made of metals and/or inorganic oxides.

Abstract: A silicone-epoxy resin is mixed with a conductivity enhancing agent, such as carbon black, and is cured to control the resistivity of films that may be used as mold release agents in mold processing or mold shaping electrically sensitive energetic compositions, such as rocket fuels, explosives, gas generator fuels and the like. The uncured precursor to the mold release agent is placed as a coating on molds that are used in these processes. Upon curing on the mold, the enhanced conductivity of the film permits dissipation of static electricity from the electrically sensitive energetic compositions.

Abstract: Dispersions of waxes in water are now widely used as molding aids, mold release agents, and the like but often leave troublesome residues that can not be easily washed away with water. This problem can be avoided by use instead of a solution in water of certain organic materials, preferably a combination of glycerine and an alkyl imidazoline surfactant.

Abstract: A process for manufacturing a capital for an architectural column. The inside of a mold for an architectural column is lightly coated with a mold release. A first opening of the mold is placed upon a surface, and a plug is positioned on the surface within the first opening. Through another opening foam is poured around the plug. After the foam has hardened, the mold is removed from the surface. All other openings in the mold are securely covered. Then an elastomer is introduced into the mold, and the mold is rotated about three different axes. The introduction of the elastomer is repeated after the prior coating created by the introduced elastomer has become tacky but before the prior coating has become firm. After the final coating of elastomer has become tacky but not firm, foam is introduced into the mold.

Abstract: A process for manufacturing a capital for an architectural column. The inside of a mold for an architectural column is lightly coated with a mold release. A first opening of the mold is placed upon a surface, and a plug is positioned on the surface within the first opening. Through another opening foam is poured around the plug. After the foam has hardened, the mold is removed from the surface. All other openings in the mold are securely covered. Then an elastomer is introduced into the mold, and the mold is rotated about multiple different axes. The introduction of the elastomer is repeated after the prior coating created by the introduced elastomer has become tacky but before the prior coating has become firm. After the final coating of elastomer has become tacky but not firm, foam is introduced into the mold.

Abstract: A powder pressing apparatus comprises an upper punch and a lower punch for compression of a powder in a cavity formed in a through hole of a die. A gap between a side surface of the lower punch and a side surface of the through hole of the die is sealed by a sealing member. A lubricant is supplied with a gas from a nozzle in the side surface of the lower punch to the side surface of the through hole, and the lubricant applied to the side surface of the through hole is spread by an absorbing member. The cavity is filled with the powder while the cavity is under suction by a reduced pressure provided from the nozzle in the side surface of the lower punch. During the suction, a filtering member provides filtration for the lower punch not to draw the powder in.

Abstract: A process is described for making gourd molds useful in the production of decorative ceramic and other articles which bear the textures of the gourd interior. Articles produced may also serve as models for use in the manufacture of production molds. Steps in making the gourd molds include selection, cutting, and removal of pulp; steps in using the gourd molds include treating with a release agent, casting, and removal of the gourd mold from the molded article.

Abstract: A powder pressing apparatus comprises an upper punch and a lower punch for compression of a powder in a cavity formed in a through hole of a die. A gap between a side surface of the lower punch and a side surface of the through hole of the die is sealed by a sealing member. A lubricant is supplied with a gas from a nozzle in the side surface of the lower punch to the side surface of the through hole, and the lubricant applied to the side surface of the through hole is spread by an absorbing member. The cavity is filled with the powder while the cavity is under suction by a reduced pressure provided from the nozzle in the side surface of the lower punch. During the suction, a filtering member provides filtration for the lower punch not to draw the powder in.

Abstract: The addition of thin coatings (less than and approaching monomolecular coatings) of persistent release materials comprising preferred compounds of the formula:

Abstract: A concrete column forming tube is provided for receiving poured concrete therein to produce a concrete column and which eliminates spiral seam lines and other undesirable characteristics on the outside surface of the formed concrete column and provides a construction which may be easily removed from the concrete column. The forming tube includes a spirally-wound cylindrical paper tube including multiple plies of paper adhered together, a centrifugally-cast plastic coating sprayed on an inside wall surface of the spirally-wound paper tube for producing an inside coated surface having a thickness and smoothness sufficient to eliminate spiral seam lines and other undesirable characteristics, and a tear strip positioned between the inside surface of the cylindrical paper tube and the plastic coating before centrifugal-casting and extending longitudinally of the forming tube over the entire length thereof and having a predetermined width and readily detachable from the plastic coating.

Abstract: A mold for producing molded fluoroelastomer parts has a mold cavity, a gate, and a runner and a sprue through which the gate communicates with an injection molding machine wherein an inorganic filler-containing crosslinkable liquid fluoroelastomer composition is injected into the mold cavity through the gate. The gate portion of the mold is surface treated with diamond-like carbon and has a cross-sectional area where it opens out into the mold cavity of 0.075-10 mm2. This combination of features lowers wear at the mold gate, thereby increasing the useful life of the mold, and also improves the mold release properties.

Abstract: A female mold for plastic sanitaryware manufacture has an open top to promote improved air escape from the mold as resinous backing resin fills the mold in order to reduce the number of gas inclusions within the backing material after it is cured. The female mold also provides thermal insulation for the curing backing material to permit better curing and to reduce the potential for delamination in the finished product. A production fixture is equipped with a gas impermeable lid for selective contact with the female mold, after the air has been expelled from the mold, in order to control undesirable styrene emissions.

Abstract: An annular die designed to produce polymer foam using only one or more ambient gasses as a blowing agent includes an exiting channel with an exit having a cross-sectional area between about two and about ten times that of a smallest point within the exit channel. The section of the die from the smallest point to the exit is thermally isolated from the rest of the die, and the temperature thereof is independently controlled. In addition, the interior surface of the exit channel is coated with a friction-reducing coating.

Abstract: A method and a system for fabricating articles made from thermoset resins using an ionic mold release agent. The invention uses a mold having a metal oxide surface with enhanced mold release characteristics. The release agent is applied internally in the resin composition or externally on the metal oxide surface. The method includes providing a mold, forming a metal oxide surface on the mold, providing an ionic release agent, providing the acid or base conjugate of the release agent at the metal oxide surface, providing a thermoset resin in the mold, and curing the resin in the mold. A method of using float glass having a SnO2 enriched surface, wherein the method includes the steps of providing an ionic release agent externally to the tin oxide surface, is also disclosed.

Abstract: A method and apparatus for ultrasonic assisted deposition of a release agent onto a workpiece is disclosed. The release agent can be any fluorinated or non-fluorinated phosphorous-containing organic acid. The workpiece can be any workpiece desired to be coated with the release agent, such as a surface needing an anti-stick coating required in a plastic casting or injection mold. Metal oxide workpiece surfaces strongly bond to fluorinated phosphorus-containing organic acids.

Abstract: A method of forming a cannula by forming a cannula mandrel assembly having a nare mandrel, a main body mandrel and mouthpiece mandrel; heating the cannula mandrel assembly, applying a polymeric material to the cannula mandrel assembly to provide a desired material thickness on the mandrel assembly to form the cannula, curing the polymeric material of the formed cannula and extracting the mandrel assembly from the cannula by disassembly and removal of the mandrel assembly parts.

Abstract: A method of forming a cannula by forming a cannula mandrel assembly having a nare mandrel, a main body mandrel and mouthpiece mandrel; heating the cannula mandrel assembly, applying a polymeric material to the cannula mandrel assembly to provide a desired material thickness on the mandrel assembly to form the cannula, curing the polymeric material of the formed cannula and extracting the mandrel assembly from the cannula by disassembly and removal of the mandrel assembly parts.

Abstract: A U-shaped bumper guard system for gas stations, parking and other vehicular areas and the like that enables easy removal of a damaged bumper guard and re-installation of a replacement guard without the need to cut or dig the concrete around the damaged guard legs that are secured in the foundation concrete. Features include securing tubular base members positioned upright in the concrete foundation layer, applying a liner within each base member, positioning one leg of the U-shaped guard into each base, and pouring concrete or the like into the liner and in contact with the leg outer surface. The liner prevents adherence between the concrete and the inner surface of the base member so that if damaged, the unit and base member concrete can be easily raised free from the base member and replaced with a new bumper guard, liner, and securing concrete since neither the foundation layer nor the base members are damaged or moved.

Abstract: The invention comprises a mold useful for the preparation of a polyurethane based article comprising a metal coated on the surfaces to come in contact with the polyurethane materials wherein the coating is a continuous matrix of cobalt or nickel having dispersed in such discontinuous matrix a fluorinated polyolefin polymer.

Abstract: An apparatus and method of manufacturing seal rings. The apparatus and method ensures that there is no wasted material during the manufacturing process and further ensures that the seal ring is manufactured to exacting standards without the need for any further milling processes. The apparatus and method has a mold which is heated and rotated at a predetermined rotation rate. A molten material is poured into the mold during the rotation thereof. The mold is then cooled and the rotation is decelerated so that the solidified material can be removed therefrom.

Abstract: A method for manufacturing a transfer member suitable for use in an image forming system. A liquid polymer is applied to an internal surface of a rotating drum, spun flat, and cured in place. Additional components of the belt are applied to the rotating mold to form a multi-layered transfer member.

Abstract: A process for embossing hydrophobic polymers with metallic embossing dies or embossing rolls, where the embossing dies or embossing rolls are hydrophobicized prior to the first embossing procedure. An embossing die or embossing roll for embossing hydrophobic polymers is also provided.