Abstract: A novel process for producing mouldings, especially contact lenses, is described, comprising the following steps: a) introducing into a mould a prepolymer containing photo crosslinkable groups that is liquid at room temperature or is readily meltable and is substantially free of solvents; b) initiating the photo cross-linking for a period of <20 minutes; c) opening the mould, so that the moulding can be removed for the mould. In accordance with the process according to the invention, it is possible especially to produce contact lenses having valuable properties.

Abstract: The invention relates to moulded ophthalmic articles, especially contact lenses, which are obtainable by cross-linking a prepolymer which is the copolymerization product of (a) at least one polyalkylene glycol of the formula (1): HO--(CH.sub.2 --CH.sub.2 --O).sub.n --(CHY.sub.1 --CHY.sub.2 --O).sub.m --(CHY.sub.3 --CHY.sub.4 --O).sub.p --H or (1'): HO--[(CH.sub.2 --CH.sub.2 --CH.sub.2 --CH.sub.2 --O--)].sub.q --H, (b) at least one polyhydroxy compound selected from the group consisting of (I) a linear or branched aliphatic polyhydroxy compound of the formula (2): R.sub.1 --(OH--).sub.x or a polyether polyol or polyester polyol derived therefrom, and (ii) a cycloaliphatic polyol selected from the group polyhydroxy-C.sub.5 -C.sub.8 -cycloalkane and unsubstituted mono- or disaccharide, (c) at least one di- or polyisocyanate of the formula (3): R.sub.2 --(NCO).sub.

Abstract: A polymer which can be crosslinked by high-energy radiation and contains from 0.1 to 50% by weight, based on the polymer, of 2,3-dihydrofuran groups or derivatives thereof, each calculated as 2,3-dihydrofuran.

Abstract: Efficient and consistent processes for manufacturing moldings, especially ophthalmic lenses such as contact lenses. The processes comprises a series of improvements, including improvements in the areas of conditions for dispensing liquid prepolymer into lens molds, male and female mold mating, reusable molds, mold cleaning, lens separation from molds (demolding), lens handling, and in-line inspection. Cyclic series of processing steps are also disclosed. Additionally, an improved molding tool is disclosed, with the molding tool including a male mold housing and a female mold housing, each of which have disposed therein a plurality of mold halves.

Abstract: A vulcanized rubber-metal plate composite is obtained by overlaying a plurality of unvulcanized rubber layers and metal plates alternately and heating thereof by magnetic induction heating. The vulcanized rubber-metal plate composite is obtained by placing a composite of a plurality of unvulcanized rubber layers and metal plates, each being overlaid alternately, into a place affected by an induction coil; heating the metal plates due to eddy currents formed in the metal plates by applying an alternating current to the induction coil; and vulcanizing the unvulcanized rubber layers due to heat conduction from the heated metal plates.

Abstract: The invention relates to a novel process for producing mouldings, especially contact lenses, which comprises the following steps: a) preparing a substantially aqueous solution of a water-soluble prepolymer that contains crosslinkable groups; b) converting the resulting solution into the solid state; c) introducing the resulting solid-state solution into a mould; d) converting the solid-state solution into the liquid state in the mould; e) where applicable closing the mould; f) initiating the crosslinking; g) where applicable opening the mould, so that the moulding can be removed from the mould.

Abstract: The invention relates to a process for heating polymer material, including irradiation of said polymer material with infrared radiation. In accordance with the process according to the invention the infrared radiation has wave lengths which substantially are not equal to the absorption peaks of the polymer material in respect of infrared radiation.

Abstract: Unsaturated polyester resin-based ophthalmic lens compositions that are modified for unexpected improvement in speed of manufacture while maintaining uniform, low optical distortion and/or improved tint speed by the addition to the polyester composition of at least one photoinitiator, preferably having at least some activity at a wavelength above about 380 nm so that a UV-absorbing compound can be included in the polyester lens composition, and the polyester resin composition is photocured to gelation in about 7 minutes or less, e.g., using a light intensity of at least about 300 microwatts/cm.sup.2, more preferably at least about 500 microwatts/cm.sup.2, most preferably at least about 1,000 microwatts/cm.sup.2.

Abstract: A novel method for producing thick composite parts based upon photopolymerizable compositions is disclosed. Also disclosed are novel methods for encapsulation of microelectronic devices based upon novel photopolymerizable compositions. The constituents of the photopolymerizable mixture comprise a monomer or monomers capable of polymerizing by free radical or cationic mechanisms, and a photoinitiator system which possesses an absorbance characteristic which is effectively reduced, or self-eliminating, upon initiation of the polymerization reaction. Parts having thicknesses up to 2 cm and thicker for varying end use applications are made by photopolymerizing such compositions. In addition, using such compositions composite parts can be made using a reinforcement material such as a glass fiber mat present in an amount by weight of from about 5 to about 70%.

Abstract: An apparatus and method for assembling a lens-forming structure, the structure having a front mold, a rear mold, and a gasket defining an axially extending bore, including a collet for supporting the gasket so that at least one of the front mold or the rear mold are insertable into the bore thereof, a robotic arm for inserting the front mold into the bore of the gasket, and a piston for inserting the rear mold into the bore of the gasket. The piston axially moves within the bore of the gasket a selected one of the front mold or the rear mold relative to the other mold to a desired one of a plurality of axial separation distances between the molds. Alternatively, the robotic arm can move the selected mold relative to the other mold.

Abstract: Methods for making tubular pressure vessels from polymer-impregnated fibrous material utilize cylindrical mandrels that are helically wound while rotating about a horizontal axis. After end closure fittings are installed on the mandrel, a barrier layer having a thickness of about 0.015 in is created by helically winding a strip of nonwoven polyester fiber material which is impregnated and coated with a mixture of two resin systems, one which is promptly cured by UV radiation while the other remains uncured. The resultant barrier layer is stable and drip-free and is inspected so minor defects can be remedied. A time lag of several hours before winding the major portion of the sidewall of the barrier layer subassembly is completely acceptable if an epoxy resin plus acid anhydride curing agent system is used having an extended pot-life of 12 to 15 hours.

Abstract: A core winding a web of deformable material which is thicker along its margins, particularly knurl-edged webs. The core includes a rigid cylindrical member and a deformable cover supported by the rigid member. First and second detachable end members are adapted for attachment to the ends of the rigid member. The hardness of the end members is harder than the deformable cover such that the knurled margins overlay the end members.

Abstract: Disclosed are (1) an optical resin composition comprising Component A: a thiourethane prepolymer compound prepared by reacting a polythiol compound having at least 3 functional groups and an intramolecular sulfide bond, with a polyisocyanate compound in a molar ratio of --SH to --NCO ranging from 3.0 to 7.0; Component B: at least one (meth) acrylate compound having at least 2 functional groups; and Component C: a compound radically polymerizable with Components A and B, in 10 to 50% by weight, 35 to 70% by weight, and 5 to 30% by weight, respectively; (2) a preparation process for an optical resin by photopolymerization; (3) an optical resin; and (4) a prepolymer suitable for Component A. The composition is a novel, rapidly polymerizable composition for an optical resin. Furthermore, a resin prepared by curing the composition not only has a high refractive index and a high Abbe number, but also is excellent in transparency and optical homogeneity.

Abstract: A method of molding a composite insulator having a core member and an overcoat portion arranged on an outer surface of the core member, in which a core member having metal fittings at both ends thereof is set in a metal mold for molding the composite insulator, overcoat portion forming materials are filled in a cavity for molding said overcoat portion formed around the core member, and then the overcoat portion forming materials are cured by heat, is disclosed. The improved method includes a step of making a temperature increase of the overcoat portion forming materials near the metal fittings equal to that of the other portion, when the overcoat portion forming materials are cured by heat, by utilizing an additional heating means.

Abstract: A photocurable resin composition comprising (A) at least one urethane di- or triacrylate, which is a novel compound, (B) a radical polymeriable compound, and (C) a photopolymerization initiator, the weight ratio of the urethane acrylate (A) to the radical polymerizable compound (B) being 65/35 to 25/75; a method of producing a photo-cured object by photo-curing the above composition; a vacuum casting mold obtained by the above method; and a vacuum casting method using the above mold.

Abstract: Process for producing coatings or moldings by radiation curing, which involves using high-energy light to irradiate radiation-curable compositions containing 1-100% by weight, based on the total amount of free-radically or cationically polymerizable compounds, of compounds A) containing at least one cationically polymerizable 2,3-dihydrofuran structure.

Abstract: The invention relates to a novel process for the production of mouldings, in particular contact lenses, in which a crosslinkable polymer comprising units containing crosslinkable groups, units containing a bound photoinitiator and, if desired, units containing further modifiers is crosslinked in solution, and to mouldings, in particular contact lenses, obtainable by this process. The present invention likewise relates to novel crosslinkable polymers which can be employed in the process, in particular derivatives of a polyvinyl alcohol having a molecular weight of at least about 2000 which comprises from about 0.5 to about 80%, based on the number of hydroxyl groups in the polyvinyl alcohol, of units of the formula I ##STR1## in which the variables are as defined in the description, and units of the formula IV, as defined in the description, which contain a bound photoinitiator.

Abstract: A medical instrument capable of maintaining medicament liquids such as pharmaceuticals, nutriments in high quality and dosing correctly and sanitarily is provided. This medical instrument comprises a material containing a resin formed of a cyclic olefin compound or a bridged polycyclic hydrocarbon compound, as a polymeric component.

Abstract: A flexible glass fiber reinforcement material has microwave-sensitive or ultraviolet sensitive binder added and is formed into a desired shape. Selected electromagnetic energy (microwave or ultraviolet) is then applied to cure and rigidize the binder. A mold for shaping the reinforcement material comprises a mold cavity defined by microwave or ultraviolet transparent material divided into separate and separable mold parts and, for microwave applications, each part carries one half of a split microwave waveguide which directs microwave energy to cure the binder resin when the mold is closed. For ultraviolet applications, an ultraviolet source (or sources) is located in the mold. Energetic stitching of a reinforcement rib is performed by applying a binder resin to the rib at at least one location, placing that location into contact with a preform and curing the binder resin to bond the parts together.

Abstract: A process for manufacturing simple or complex reinforcement preforms for use in resin transfer molding (RTM), structural reaction injection molding (SRIM) or similar molding processes includes applying a thermosetting binder, which is sensitive to selected ultraviolet or microwave radiation, to planar woven or non-woven reinforcing materials, the binder-bearing reinforcing material being placed into a three-dimensional mold and pressed into a desired shape, cured in the mold by applying a corresponding selected ultraviolet or microwave energy thereto to cure and rigidize the binder and hold reinforcement material in the three-dimensional shape resulting in a rigid three-dimensional preform to be used in subsequent molding operations. Structural reinforcements, sub-assemblies and the like may be applied to the preform to enhance the final properties of the final composite structure.

Abstract: An embossed substrate comprising a substrate of a plastic material and having a surface and an embossed surface carried by the surface of the substrate. The embossed surface is characterized by having a pattern with an average roughness of between 100 nanometers and 300 nanometers with the roughness being distributed substantially uniformly over the surface, the pattern has ridges and valleys with the horizontal distance between adjacent ridges and/or valleys being greater than the depth between the ridges and the valleys. The peaks and the valleys are randomly disposed without periodicity to cause diffusion of light impinging thereon to minimize or eliminate interference effects when the embossed surface overcoated with thin planar organic layers is exposed to light.

Abstract: A photo-curable liquid silicone rubber composition is curable upon exposure to light into a cured product having a Shore A hardness of 20 to 60 and a light transmittance of at least 10% at a wall gage of 10 mm. The composition is suitable for forming a transparent templating mother mold which allows a photo-curable liquid resin cast therein to be cured with light transmitted by the mold wall.

Abstract: Uncured thermoset composite reactants containing ultraviolet curable reagents may be effectively cured by pultrusion using a unique molding die which uniformly irradiates the uncured composites contained within the die. The die includes strategically positioned passageways communicating through the chamber walls of the die to the die chamber. The passageways are equipped with fiber optic cables connected to an ultraviolet generator at one cable end and ultraviolet discharging end for discharging ultraviolet radiation within the die chamber at an opposite cable end. Ultraviolet light conducted to the die chamber by the fiber optic cables uniformly initiates and catalyzes the uncured reactants to produce a fully cured thermoset composite. Uncured composite reactants may be continuously fed to the die as the cured composites are continuously withdrawn from the die.

Abstract: Laminated, molded plastic articles having an excellent abrasion resistant coating are prepared by a 2-step process including applying to a mold surface a 100% reactive coating composition, at least partially curing the coating composition, applying to the exposed surface of the cured coating composition a thermoplastic material, and curing the thermoplastic material to form the laminated molded article. The coating composition includes a polyfunctional acrylic monomer, such as dipentaerythritol monohydroxypentacrylate, a mono functional acrylic monomer, such as hydroxymethylacrylate, an acrylic-soluble thermoplastic, such as cellulose acetate butyrate, an aminoplast resin, such as melamine-formaldehyde, and a free radical initiator. The coating composition is at least partially cured by either UV or IR radiation.

Abstract: Method and apparatus of making a reinforced composite structure wherein a reusable mold closure is mated to a mold to close off a mold cavity in which a reinforcement is positioned. The mold closure or mold includes a plurality of collapsible resin supply ports through which resin is pumped into the mold cavity from a source of resin to infuse or impregnate the reinforcement with resin. After the resin is introduced into the mold cavity, the resin residing in the resin supply ports is selectively cured to form respective cured resin plugs on which the resin supply ports collapse to seal them in air-tight manner. The resin residing in the mold and infused in the reinforcement is not cured at that time.

Abstract: An improved process for molding parts such as gaskets using an injection molding machine including upper and lower mold plates which are transparent to UV light and have pattern recesses of differing sizes and spaced apart locations, a UV light source, and a low pressure injection system for delivering elastomers to the mold plates. The elastomers are cured by exposure to UV light. An optional carrier plate may be inserted between the mold plates and provides a rigid surface for attachment of the elastomer. The carrier plate selectively covers the pattern recesses located in the mold plates.

Abstract: A process for preparing a cross-linked polymeric article, which process includes: providing a cross-linkable polymeric casting composition; and a photochromic composition; subjecting the cross-linkable polymeric casting composition to partial cure, such that the polymer reaches or exceeds its point of gelation; contacting the partially cured gelled polymer with the photochromic composition; and curing the gelled polymer.

Abstract: The invention relates to a novel process for the production of tinted mouldings, in particular tinted contact lenses, in which a crosslinkable tinted polymer comprising units containing a crosslinkable group and units containing a reactive dye radical is crosslinked in solution, and to tinted mouldings, in particular tinted contact lenses, obtainable by this process.

Abstract: The method and apparatus for making a preform which is a rigid shaped item formed of glass fibers rigidly joined to each other where adjacent fibers touch. The interstices between the fibers are unfilled for the use of matrix resin to subsequently form a molded article. The preform is formed by shaping fibers into the preform shape, applying a binder to the fibers so that they are coated at the locations where they touch. The binder is sensitive or responds to the application of electromagnetic energy. In completing the preform after the application of the binder, the preform is subjected to electromagnetic energy so that the binder hardens to form a rigid preform. In one species form, the electromagnetic energy is applied in the form of microwave energy. The application of electromagnetic energy causes a reaction in the binder without requiring heating of the glass fibers so that the preforms can be rigidified rapidly and efficiently.

Abstract: A process for producing a shaped product, which includes polymerizing a mixture comprising an iniferter and a radical polymerizable monomer to obtain a half polymer having a rate of polymerization of from 5 to 90 wt %, filling the half polymer in a predetermined cavity and then applying a polymerization energy again to the half polymer to complete polymerization.

Abstract: A novel method for producing thick composite parts based upon photopolymerizable compositions is disclosed. The constituents of the photopolymerizable mixture comprise a monomer or monomers capable of polymerizing by free radical or cationic mechanisms, and a photoinitiator system which possesses an absorbance characteristic which is effectively reduced, or self-eliminating, upon initiation of the polymerization reaction. Parts having thicknesses up to 2 cm and thicker for varying end use applications are made by photopolymerizing such compositions. In addition, using such compositions composite parts can be made using a reinforcement material such as a glass fiber mat present in an amount by weight of from about 5 to about 70%.

Abstract: A method of manufacturing a card with a built-in electronic part including a first step of mounting an electronic part, such as an LSI module, on a first bottom-covering material, applying a first molten resin onto the first bottom-covering material and the electronic part, and placing a first top-covering material on the fist molten resin. A second step includes curing the first molten resin, thereby forming a first structure of at least the first cured resin and the electronic part, and mounting the first structure on a second bottom-covering material. A third step includes applying a second molten resin onto the first structure and placing a second top-covering material on the second molten resin. A fourth step includes curing the second molten resin, thereby forming a second structure of at least the second cured resin and the first structure. A fifth step includes cutting the second structure thereby forming a card.

Abstract: Various forms of light-diffusing screen are disclosed comprising plastics sheets having surface texturing of some kind, adding to or modifying the diffusing effect. The plastics sheets may have bulk diffusing characteristics in addition to the surface texturing. The surface texturing may be produced by, for example, embossing or by molding the plastics against a textured surface such as a "brushed" surface or a ribbed or grooved surface imparting asymmetrical diffusion characteristics to the screen.

Abstract: A laminate molding method of fabricating a desired shape consisting of laminate layers having a first type layer in a completely solidified state, the method includes a first step of forming a second type layer on the first type layer, the first type layer having a viscosity larger than the second type layer, a second step of forming a slot groove in the second layer, the second type layer having first and second regions, a third step of printing a releaser on a predetermined region of the second type layer, a fourth step of forming a third type layer on the second type layer or on the first type layer, the second type having a viscosity larger than the third type layer, a fifth step of solidifying the third type layer to form the first type layer, and a sixth step of repeating the first, second, third, fourth, and fifth steps as desired.

Abstract: A rigid three-dimensional preform is made by moving a plurality of webs of fibrous reinforcement material superposed and coplanar to a cutter, the webs being coated with an electromagnetic energy-curable binder and pressed together. Prior to cutting a blank in a two-dimensional development of the three-dimensional preform from the webs, the webs are tacked together at spaced local zones by locally curing the binder at those zones by locally applying the appropriate electromagnetic radiation (microwave, ultraviolet, electron) so that the webs travel as one to the cutter. After cutting of the blank, the blank is loaded into a mold to replicate the three-dimensional shape of the preform and the remainder of the binder is cured in the mold by the application of the appropriate electromagnetic radiation.

Abstract: A female mold (2, 12, 22, 32, 42, 52, 62) having a desirable pattern is formed on a substrate (1, 11, 21, 31, 41, 51, 61). Next, ceramic material (3, 13, 23, 33, 43, 53, 63) is filled in spaces in the female mold. Thereafter, the female mold is removed by heating the entire substrate, whereby a desirable thick film pattern can be finely and easily formed. The inorganic paste material comprising inorganic liquid vehicle containing water glass as main ingredient and powdery solid dispersed in the inorganic liquid vehicle is used as the ceramic material. The volume change of the inorganic paste material is small during the drying and calcinating processes, thus the inorganic paste material is prevented from being broken.

Abstract: In a process for the manufacture of mouldings, especially optical lenses, specifically contact lenses (CL), a starting material that is crosslinkable by the impingement of suitable energy is introduced into a mould (1) having a cavity (15), which mould is at least partially permeable to the energy concerned. The starting material is introduced into the cavity in a still at least partially uncrosslinked state, the mould cavity determining the shape of the moulding (CL) to be produced. By means of impingement of the energy concerned, the starting material is crosslinked to an extent sufficient for it to be possible for the moulding (CL) to be released from the mould. The filling of the mould cavity is carried out in the starting material that is still at least partially in the uncrosslinked state.

Abstract: An intravascular catheter system for implanting a radially expandable stent within a body vessel including a catheter comprising an inner lumen tube, an inflation lumen tube, an inflatable balloon and at least one free standing built-up layer affixed to the outer diameter of the inner lumen tube, the built-up layer being internal to the balloon. A stent is mounted coaxially upon the balloon, the built-up layer extends coaxially within the stent but does not extend beyond the proximal and distal ends of the stent. The built-up layer is sufficiently thick as to cause the balloon to expand evenly and the stent to deploy uniformly. The method of manufacturing the built-up layer includes forming the layer from shrink wrap tubing or alternatively forming the layer from molded ultraviolet light curing adhesive.

Abstract: A transparent mold system (TMS) allows rapid and economical production of thermoset fiber reinforced plastics (FRP) and other thermoset resin parts by heating with visible light energy without using an autoclave, photosensitive resins, or ultraviolet (U.V.) sensitive chemical curing agents. Molding times are accelerated to minutes instead of hours, and the molds are made of transparent plastics materials that can be economically produced by injection, casting, vacuum or pressure forming to replace metal molds and laid-up FRP molds.

Abstract: A unique composite material impregnated with a heat curable resin comprising a layer of conductive fibers and one or more resin carrying layers is utilized to reinforce utility poles by wrapping the material around a portion of the utility pole and causing a current to flow through the conductive fibers to resistively heat the material to the resin. The composite material can also be incorporated into molds to produce cured composite parts. The composite material is also used in the construction of large parts without the need for huge, expensive molds. The conductive fibers in composite parts are oriented in a manner to ensure that the entire part is thoroughly heated during the curing process.

Abstract: An arrangement is provided for a method of manufacturing optically readable discs in which a substrate is placed on a movable substrate carrier and by moving the substrate carrier it is subsequently placed in a centered position on a previously applied amount of replication material on a mold. In this position the substrate is fixed to the mold, after which the substrate carrier releases the substrate and the replication layer in the structure zone is solidified.

Abstract: A method of replicating an optically flat surface includes providing a plastic optical element having a machined flat surface. The machined flat surface includes a plurality of ridges thereon. A coating material is applied to an optically perfect flat and the optical element is rolled and positioned on the coating material applied to the optically perfect flat such that grooves between the ridges with the coating material. The coating material sandwiched between the optical element and the optically perfect flat is cured and the optically perfect flat is removed from the cured coating material.

Abstract: A tire vulcanization apparatus in which an encaser 3 makes it possible to introduce a tire into a mold 1 and, by means of inductors 42, transfers to the mold heat energy necessary for vulcanization and in which a chamber 5 receives several molds 1 and makes it possible to maintain each mold insulated from the environment in order to limit heat losses during the time necessary for the vulcanization.

Abstract: A method for fabricating an individually adapted in-the-ear hearing aid shell with a battery compartment cast into the shell such that the door of the battery compartment is flush or slightly recessed in the portion of the shell that contacts the user's ear cavity.

Abstract: A three-dimensional complex preform is made formed of various types of reinforcement fiberglass fibers with a binder at the interstices which rigidize the preform to the shape and form approximating the molded article, which can be handled and stored until a final mold is made filling the interstices with plastic and curing the plastic. Complex preforms require either specific reinforcements in the form of increased sections, specific reinforcement, or require modification or enlargement in size or increase in complexity by the attachment of one or more additional preforms. To modify an existing preform and obtain a desired shape and form, reinforcement members or additional preforms are attached by energetic stitching. Energetic stitching includes the application of an electromagnetic energy curable binder and the application of electromagnetic radiation to cure the binder.

Abstract: A lining and method for in situ rehabilitation of a pipe. The lining includes a tubular shaped resin impregnated composite having a conductive layer surrounding an inflatable bladder. The method includes the steps of positioning the lining within a pipe section, inflating the bladder until the lining is in contiguous contact with the interior of the pipe and inducing an electric current through the conductive layer to resistively heat the lining and cure the impregnated resin.