Abstract: A method and apparatus for making a preformed maskant sheet having a plurality of perforations corresponding to a pattern of perforations desired in a structure. A shaping surface is prepared on a sheet having the contours of the structure to be perforated. The surface is perforated in the precise desired pattern. A plenum is secured and sealed to the back of the shaping sheet, enclosing all of the perforations. A line for introducing air into the plenum is connected to the plenum. A coating of maskant material is sprayed onto the surface (which has mold release properties) while positive air pressure is maintained in the plenum. Air flows out through the perforations, keeping them clear of maskant. The maskant is then cured and the resulting self-supporting sheet is removed from the surface and placed against the structure to be perforated. The holes may then be formed by any suitable method, such as grit blasting etching or the like.

Abstract: A novel process for preparing a pre-cast terrazzo panel having detailed, multicolor designs therein constituted by background and inlay designs of different colors. The inlay and background colors are integral with no surface difference between the inlay and the background. The process involves the steps of (a) providing a pre-cast unpolished terrazzo panel with a first background color; (b) cutting out an inlay pattern or design in the terrazzo panel to create a silhouette cut-out panel; (c) placing the cut-out panel in a mold, pouring a blend of a second color comprising a binder and aggregate into the cut-out and curing the blend to create a cured inlay of a second color in the panel; (d) repeating steps (b) and (c) as often as desired with blends having colors the same or different from the first and second colors; and (e) polishing the resulting panel to produce a terrazzo panel having a plurality of colors.

Abstract: A novel method is provided for reticulating adhesive-backed, perforated substrates. The method entails tacking a continuous sheet of viscous reticulating adhesive to one side of the substrate and then contacting the other side with heated air. The temperature of the air is regulated such that the adhesive softens and bubbles over the perforations but final cure is not initiated. The air is directed at a velocity such that the bubbles burst and the adhesive is redeposited onto the adhesive-side of the substrate.

Abstract: An apparatus for texturing the surface of wet cast plastic acoustical composition during manufacture of acoustical tiles by use of spinning air rolls. In the apparatus, at least one hollow cylindrical roll that is perforated in a random manner is suspended over the surface of wet cast plastic acoustical composition, the roll being driven by a motor. The interior of the roll is preferably provided with a perforated air tube or pipeline, from which issues uniform air pressurization of the spinning roll vessel. By providing differential speed of the roll in contrast to the line speed of the wet plastic composition and different air pressurization of the roll, a wide variety of textures may be produced on the surface of the wet plastic acoustical composition.

Abstract: A deep drawn, synthetic-foil-sealed textile with foamed backing is perforated by applying hot pressurized air towards the foil, locally and in discrete spots, so that the foil melts locally, and foil material is blown into the textile under formation of a perforation duct that is bonded to the textile material underneath.

Abstract: Thermoplastic film, permeable to liquids, used particularly as a covering film for absorbent material, whose openings are formed as projections on one side only of the film, and having its narrowest cross-section in a plane different from that of the smooth side of the film. The cross-section of the opening widens on passing from its narrowest point towards the free edge of the projection on film. The free edge of the projection can be irregularly lobed or wrinkled.

Abstract: Apparatus for uniformly macroscopically expanding and, if desired, aperturing a plastic web. This is preferably accomplished by supporting the plastic web on a moving three-dimensional forming structure which is supported in a fluid pressure differential zone by a stationary support member. By providing a relationship between the size and pattern of the apertures in the stationary support member and the size and pattern of the apertures in the three-dimensional forming structure, substantially all of the apertures present in the forming structure are unobstructed by the stationary support member at some point during the forming structure's traverse of the fluid pressure differential zone. Thus the resultant plastic web is uniformly debossed and, if desired, apertured in the pattern of the three-dimensional forming structure.

Abstract: A method of forming a hole in a plastic pipe feeds a plastic layer for the plastic pipe from a nozzle about a mandrel into chill moulds being displaced along an elongated mould cavity about the mandrel formed by the chill moulds. All of the plastic layer is pressed into the chill moulds with a pressure medium between the mandrel and all of an inner surface of the plastic layer for forming the plastic pipe therefrom. Only portions of the plastic layer of the plastic pipe are then subjected to a local pressure difference exceeding the breaking limit of the plastic layer between the inner surface and an opposite, outer surface of the plastic layer at least in part from a flowing medium for forming a hole in the plastic layer of the plastic pipe, the flowing medium being one of a gas and a liquid and flowing from the mandrel at a pressure higher than that of the pressure medium pressing the plastic layer of the plastic pipe.

Abstract: A softened unperforated film and a perforated die which is generally cylindrical in movement are brought into contact and exposed, in a predetermined region, to a pressure gradient oriented radially of the die. The pressure gradient causes the local penetration of the film into the holes of the die and the consequent perforation of the film itself. The movement of the die is supported in a rigid manner solely upstream and downstream of the predetermined region in the common direction of movement of the film and the die. The die itself is subjected to a pulling action, along its generatrices at least close to the predetermined region.

Abstract: Producing a concrete object by first pouring an uncured mixture into a mold and then removing undesired uncured concrete using a suctioning apparatus having a liquid supply and a suction nozzle attached to a suction channel. The concrete mixture is loosened and diluted by liquid supplied through the liquid supply. This liquid and loosened diluted concrete are suctioned through the suction nozzle and the suction channel into a tank.

Abstract: A process is disclosed for the continuous manufacture of a perforated plastic film, where the plastic film is extruded directly from the extrusion unit either onto one roller of a pair of rollers or directly into the gap between a pair of rollers (a perforating/texturing roller and a back-up roller). The hot plastic film is perforated on a roller under the influence of a vacuum and shock cooling by the flow of cold air and the coolness of the back-up roller is carried out during the perforating step, and immediately thereafter. The film is preferably textured at the same time that it is perforated, the immediate cooling setting the texture in the film.

Abstract: A method of manufacturing a building block which imitates a pile of dry stones. According to the method, the stones (10) are placed side-by-side on the bottom of a mold whose inside shape corresponds to the desired block shape, said bottom being constituted by a grating. Cement is then cast inside the mold. The cement (11) is compressed in order to force it to spread out uniformly inside the mold and to creep between the stones (10). While the cement is kept under pressure, water is projected through the bottom grating against the outside face of the block (1), so as to remove any cement which may be found thereon. Pressure is then removed from the cement and it is allowed to set. Finally the block (1) is extracted from the mold.

Abstract: Shaped articles, especially ones containing a plurality of fine through passages, are made from a composition containing a refractory particulate material by extrusion, cutting the extrudate, while vertically hanging or suspending into lengths while in the green deformable state by a high velocity water jet, and then calcining to bind the refractory particles together. Depending on the nature of the refractory material, the articles are of use as catalyst supports or precursors, adsorbents, or absorbents. The extrudate is extruded horizontally and allowed to sag into a gap between the extrusion die and a transport device, which is driven positively to maintain the degree of sag within predetermined limits, and the frequency of cutting depends on the rate of movement of the transport device.

Abstract: A method for hydraulically deforming a web of polymeric film while the film is supported on a moving forming structure to produce a novel microbubbled substantially fluid-impervious web exhibiting substantially the same consumer preferred soft and silky tactile impression and reduced noise generation levels heretofore only achievable in microapertured, and hence substantially fluid pervious polymeric webs. In a particularly preferred embodiment, the microbubbled polymeric web exhibits a fine-scale pattern of discrete mushroom shaped surface aberrations, each of said surface aberrations having its amplitude oriented substantially perpendicular to the surface in which the surface aberration originates. The method may also be utilized to produce fluid pervious microapertured webs which are known in the art. Apparatus for producing microbubbled and/or microapertured webs either in "planar" or "macroscopically expanded" form are also disclosed.

Abstract: Method for imparting a selectively apertured three-dimensional pattern to a heated plastic material which is either fed in film form from a supply roll or extruded as a melt directly onto the surface of a forming structure and subjected to a fluid pressure differential while in contact with its surface. In a preferred embodiment, the film forming structure comprises a stacked laminate of initially imperforate planar sheets having continuous patterns of apertures therein and at least one initially perforate selectively apertured planar sheet located beneath the uppermost continuously apertured sheet. The laminate forming structure is preferably tubular in shape so as to facilitate continuous plastic web processing against its outermost surface. Film to be debossed and selectively apertured is brought in contacting relation with the laminate structure and subjected to a substantially uniform fluid pressure differential on said forming structure while at a temperature above its softening temperature.

Abstract: Method and apparatus for uniformly macroscopically expanding and, if desired, aperturing a plastic web. This is preferably accomplished by supporting the plastic web on a moving three-dimensional forming structure which is supported in a fluid pressure differential zone by a stationary support member. By providing a relationship between the size and pattern of the apertures in the stationary support member and the size and pattern of the apertures in the three-dimensional forming structure, substantially all of the apertures present in the forming structure are unobstructed by the stationary support member at some point during the forming structure's traverse of the fluid pressure differential zone. Thus the resultant plastic web is uniformly debossed and, if desired, apertured in the pattern of the three-dimensional forming structure.

Abstract: The present invention provides for a process for transforming a substantially continuous web of substantially planar, deformable material having an indefinite length, a first surface, and a second surface into a formed material. The material has a transformation temperature range. The process comprises the following steps:(a) The web of material is provided on a forming structure with the first surface of the web of material proximate a forming surface of the forming structure. The forming surface moves in a direction of the length of the web of material and carries the web of material in that direction.(b) A liquid stream is applied to the second surface of the web of material. The liquid stream has sufficient force and mass flux to cause the web of material to be deformed toward the forming surface, such that the material acquires a substantial three-dimensional conformation.

Abstract: A method for producing a fabric item comprising the steps of producing a perforated substrate in the shape of the desired fabric item, supplying fibers to the perforated substrate, causing the fibers to engage the perforations in the substrate, and retaining the fibers in the perforations.

Abstract: A continuous, multi-phase process for debossing and perforating a substantially continuous web of substantially planar polymeric film to coincide with the image of one or more forming structures, each having a patterned forming surface with a multiplicity of holes and an opposed surface. Each forming structure is open from the holes in the forming surface to its opposed surface. The web of film has an indefinite length, a first surface, a second surface and a thickness. The thickness comprises the distance between the first surface and the second surface. The process comprises at least two sequential forming phases, one of which involves three-dimensional conformance of the web to the macroscopic profile of the forming structure and another of which involves aperturing of the web to coincide with fine-scale apertures in either the same or a separate forming structure.

Abstract: A laminated, cylindrical, metal screen or molding element for vacuum perforation of plastic film or sheets, comprising two or more relatively thin cylindrical metal screens, each having a predetermined inside and outside diameter and each having a plurality of openings or holes therein of a predetermined size and geometrical shape, and said relatively thin screens stacked and bonded together, diametrically one inside the other thereby providing a screen of a desired thickness and a desired hole geometry wherein the holes in the screen have substantially straight walls perpendicular to the surface of the screen. A method of producing a relatively thick cylindrical metal screen for vacuum perforation of plastic film or sheets wherein the holes or openings in the screen have substantially straight walls perpendicular to the surface of the screen, comprising stacking and bonding together two or more matched relatively thin metal screens diametrically one inside the other.

Abstract: A resilient plastic web exhibiting a fiber-like appearance and tactile impression and method and apparatus for its manufacture. In a preferred embodiment, the web exhibits a three-dimensional microstructure comprising a regulated continuum of debossed areas of non-uniform cross-section along their length. In a particularly preferred embodiment, the debossed areas comprise capillary networks interconnecting the first and second surfaces of the web, said networks being of decreasing size in the direction of said second surface to promote fluid transport from the first surface of the web to the second surface and inhibit the flow of fluid in the reverse direction. Forming surfaces utilized to produce said webs are constructed by laminating a multiplicity of thin plates having patterns of apertures therein to form an integral structure exhibiting properties and characteristics unachievable by prior art machining and weaving techniques.

Abstract: An improved process of manufacturing a plastic helical net is disclosed. The process begins by co-extruding two or more plastic materials characterized by having different properties of contraction and orientation to form a bi-component sheet. Holes or impressions are formed in the sheet at regular intervals as by embossing, drawing, punching or slitting, and then the sheet is oriented, as by stretching, well below the melt temperature of the materials, and then releasing.

Abstract: The present invention provides a process for debossing and perforating a substantially continuous web of substantially planar thermoplastic film, using a forming structure having a patterned forming surface with holes and an opposed surface. The forming structure is open from the holes in the forming surface to the opposed surface. The forming structure moves in a direction of the length of the web of film and carries the web of film in that direction. The web of film is substantially entirely molten. A fluid differential pressure is substantially continuously applied across the thickness of the web of film from a first position along the direction of movement of the forming structure to a second position. The first and second positions are fixed relative to the moving forming structure. The fluid differential pressure is sufficiently great to cause the first surface of the web of film to be urged against the forming surface and to cause perforations to be created in the web of film.

Abstract: An apparatus for the manufacture of selectively apertured thermoplastic sheet or film, comprising a rotatable molding element means for receiving the film and which means has a predetermined pattern therein wherein as the film is contacted with the rotatable molding element means and a fluid pressure differential is applied to the surface of the film, a desired pattern of perforated areas and non-perforated areas are imparted to the film with each of said areas being continuous across the web of the film and alternating in the machine direction.

Abstract: Method and apparatus for imparting a uniformly apertured three-dimensional pattern to a heated plastic material subjected to a fluid pressure differential while in contact with said forming structure. In a preferred embodiment, said forming structure is created by forming a substantially continuous pattern of apertures in a multiplicity of planar sheets, at least a portion of said sheets having aperture patterns which are concentrically aligned but dissimilar in size to one another. The sheets having said concentrically aligned aperture patterns are thereafter superposed upon one another so as to form a stack exhibiting a three-dimensional continuum of capillary networks. A sufficient number of laminae are employed to ensure that said networks are of greater overall length than the maximum depth to which the plastic film being processed thereon is drawn when subjected to said fluid pressure differential.

Abstract: Gypsum board is formed into a continuous sheet by depositing an aqueous slurry of calcium sulfate hemihydrate, including conventional additives, between two paper cover sheets on a moving conveyor. After the slurry has reached the initial stiffening degree of set and before the slurry has reached a final or temperature rise set, and in the preferred form before it has reached a Vicat set, the moving sheet is transversely cut into individual boards by means of a high pressure and velocity fluid cutting jet. Since the cutting may be carried out before the Vicat set is reached, the board line may be operated at an increased velocity, thereby enabling a particular board line materially to increase its production within a given period of time and to use conveying equipment which is shorter in length.

Abstract: A pile-surfaced textile structure comprising a composite characterized in that a low-melting point thermoplastic resin material is fused to a backing material of an air-permeable textile structure which is not softened and thus remains substantially intact upon heating at a given temperature, and in that piles are formed from said resin material in the fibrous form.

Abstract: A perforated thermoplastic film with less than ideally shaped tapered capillaries which has an increased liquid flow rate through the tapered capillaries and a method for making such a film. The method includes forming a perforated thermoplastic film having tapered capillaries from a resin into which an effective amount of a polarizable, migrating surfactant has been blended therewith and then treating the perforated thermoplastic film with a corona discharge treatment sufficient to increase the flow rate of liquid through said perforated film and provide a film having a percent run off of from about zero to ten percent.The perforated film made in accordance with the invention has a much higher liquid transmission rate than similarly made non-surfactant treated perforated film having tapered capillaries which has been treated only with a corona discharge treatment. The latter may be conducted as the film is being formed and perforated.

Abstract: Mandrel-cured, curved elastomeric hose is provided with an indexing mark that is formed prior to or during curing of the hose on the mandrel. The rigid curved mandrel has an exterior hose-bearing surface and an interior cavity. The cavity and exterior surface are connected by a small passageway or hole which is located where the index mark is to be made on the hose. A sleeve having a wall of uncured elastomeric material is mounted on the mandrel such that a portion of the sleeve covers the passageway. The mandrel having the sleeve mounted thereon is placed in an autoclave and subjected to steam pressure. The steam pressure forces elastomer material into the passageway and thereafter cures the elastomer sleeve into a hose. The pressure inside the cavity is approximately atmospheric at the introduction of the steam pressure. The cavity within the mandrel may be sealed except for the passageway or the cavity and the passageway may be vented to atmospheric pressure.

Abstract: Method for making extruded bricks having a textured handmade appearing face designed to form on outer building wall surface, comprising the steps of feeding a column of brick-forming clay mix into a progressively narrowing inlet funnel portion of a brick extruding die, progressively constricting the clay mix column while feeding the same from said inlet funnel portion through a die throat section of the extruding die of horizontally elongated rectangular cross-section defined by downstream converging upper, lower and side boundary surfaces to shape the clay mix column to a rectangular cross-section whose width dimension perpendicular to said face slightly exceeds the desired ultimate brick width, disrupting the clay column in said die throat section at a subsurface location space near and below the uppermost boundary surface of the die throat section along a plane substantially spanning the transverse extent of the die throat section by pressurized downsteam-directed liquid jets internally disrupting the clay

Abstract: A process for the manufacture of thermoplastic sheet having elliptical perforations including a rotatable molding element having a series of hexagonal-shaped depressions having centered therein elliptical holes, the elliptical holes having a major axis and a minor axis, the major axis being oriented parallel to the direction in which the molding element is rotated, a means for applying a fluid pressure differential to a surface of the thermoplastic sheet to force the sheet against the molding element to effect rupturing of the sheet and the formation of elliptical holes in the sheet.

Abstract: Apparatus for making extruded bricks having a textured handmade appearing face designed to form the outer building wall surface, comprising a brick extruding die including a progressively narrowing inlet funnel portion having a downstream end and a constricted neck portion forming a material shaping die throat to receive a column of brick forming clay mix and shape the clay mix column to a rectangular cross-section whose width dimension perpendicular to said face slightly exceeds the desired brick width. A subsurface disrupting elongated thin bridge member transversely spans the die throat and is supplied with liquid under pressure to produce downstream directed liquid jets internally disrupting the clay mix column in the die throat immediately below the upper boundry surface thereof along a substantially horizontal disruption plane.

Abstract: The present invention relates to a process for extruding a thermoplastic sheath in the form of a tubular film provided with perforations and to a device for carrying out the process, according to which the extruded film passes over a skirt through which are blown jets of hot air provoking the perforation and formation of openings in the film; in the areas where the film is not to be perforated, air jets are also blown through channels of smaller width, therefore with a reduced pressure, so that the jets do not provoke the perforation of the film but form an air-cushion facilitating the flow of the film on the skirt; the channels are supplied from a pneumatic chamber with interposition of a rotary distributor formed by a ring made of graphite or self-lubricating material. The invention is applicable to the manufacture of partially perforated tubular films with a view to making packings.

Abstract: A forming die including a cup-shaped cavity for the vacuum thermoforming of sheets of thermoplastic material includes, in the center of its bottom, an upwardly directed pointed projection, the height of which is remarkably smaller than the depth of the said cavity. The suction bores through which vacuum is generated at the interior of the cavity are arranged at the periphery of the bottom of the cavity itself.

Abstract: An apparatus and method utilizing pressurized air discharged through positionable outlets is adapted to blowing core mark material from freshly molded, uncured concrete blocks of either the rib or flute type designed to be split or conventional unsplit blocks so as to prevent the core mark material associated with such blocks from being trapped and hardening in recesses or on surfaces of the blocks.

Abstract: The invention is a process for forming a reticulated web net oriented from a perforated film wherein the perforated film is produced by thermoforming projections or pips on an endless perforated surface and subsequently skiving the pips off flush with the film, said thermoforming, skiving and orientation all taking place in a continuous fashion.

Abstract: A method for blow molding a thermoplastic bottle of the type wherein the bottle is filled with a liquid usually water. The bottle is sealed while in the mold. Access to the contents therein is obtained through one or more breachable seals. In the present matter the bottle is supplied during the molding step with a manifold at the bottom of the bottle which acts as a diffuser in admitting air therethrough both during the molding step and during the use of the bottle for the purpose intended, i.e., humidification.

Abstract: A rotatable perforated molding element for embossing and/or perforating thermoplastic sheet or film, the molding element including a series of perforated strips having two parallel sides and two parallel ends, the sides being perpendicular to the ends, each of the strips being welded at the end prior to placing the strips on a supporting drum. Additional strips are placed on the drum until the desired area of the drum is covered with the strips.

Abstract: A method of and apparatus for uniformly debossing and perforating a ribbon of thermoplastic sheet material or film through the use of vacuum in combination with a flash heating source such as a flow of hot air. The apparatus causes a ribbon of such film to be forwarded from a supply such as a roll of thermoplastic material, thence about a circumferentially extending portion of a rotating debossing-perforating cylinder, and then downstream where the debossed and perforated film may be further processed or where it may be wound on a spool to form a roll thereof. The debossing-perforating cylinder comprises a perforated tubular member through which a plurality of independently adjustable levels of vacuum can be applied from within the cylinder to circumferentially spaced sections of the film in contact with the exterior surface of the perforated tubular member. The apparatus further causes a virtual curtain of hot air to be directed radially inwardly towards a predetermined zone of the perforated tubular member.

Abstract: Process and resulting article are disclosed wherein plastic material is passed into a mold cavity; pressurizing fluid is injected into the plastic material under controlled pressure and at a controlled rate to cause the plastic material to flow out and assume the contour of the cavity, the gas pressure being maintained until the plastic material is self-supporting. The resulting article has an outer skin and a generally hollow center containing skin-connecting structural "webs".