Abstract: A vacuum molding process for adhering a porous, foam-backed fabric 50 to a thermoplastic substrate 60 and for providing a nonplanar contour to the substrate 60 with fabric 50 adhered thereto. The porous, foam-backed fabric 50 is loosely positioned over a female mold 30. The substrate 60 is heated sufficiently for the substrate 60 to sag. The sagging substrate 60 is deposited over the female mold 30 in a manner whereby the substrate 60 contacts the fabric 50 around an effective mold perimeter 36. A vacuum applied through the female mold 30 is transmitted through the porous foam-backed fabric 50 and attracts the sagging substrate 60 into the mold 30. The attraction causes contact and adhesion of the heated substrate 60 and the foam-backed fabric 50.

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

Abstract: A non-metallic vacuum probe for elevated temperature service having a probe body portion for coupling to a vacuum line. The probe body portion is coupled through a washer shaped low friction bearing surface and gasket for sealing to a probe flange portion. Interconnection of probe body portion and probe flange portion is provided through lug and ramp means. The probe flange portion includes vacuum channels on the bottom major surface region for vacuum bag and blanket curing of plastic components or panels in autoclaves or ovens.

Abstract: The apparatus of the present invention involves transferring plastic parisons from a receiving station to a finishing station on a plurality of pallets in a single row for forming said parisons into hollow plastic articles. The pallets with parisons thereon are transported through a temperature conditioning means for temperature conditioning said parisons to render same suitable for forming into said hollow plastic articles at the finishing station.

Abstract: A method of preparing a template for a product from a sample of the product. The ultimate template is either larger or smaller in size than the sample. Initially, a mixture of liquid rubber and a curing agent is prepared. The sample is then covered with the mixture and the mixture is permitted to harden to form a temporary mold. The sample is then removed from the mold to form a cavity, and the size of the cavity in the mold is altered to either increase or decrease its dimensions. Finally, a hardenable material, such as an epoxy resin, is poured into the mold to form the template. If an enlarged template is to be formed, the size of the cavity of the mold is increased by immersing the mold in an organic solvent bath. If the size of the mold is to be decreased, an organic solvent is added to the mixture before formation of the mold, and after the mold has been formed, it is heated to shrink the size of the mold.

Abstract: A process is provided for removing volatile materials from a molten oxymethylene polymer, according to which the molten polymer is passed through a rotating disk polymer processor having at least three stages; a first devolatilization stage, then a stabilization stage and then a second devolatilization stage. The molten polymer in the first devolatilization stage is maintained at a temperature above its melting point in the temperature range of from about 160.degree. C. to about 220.degree. C. and at a vapor space pressure of from about 0.1 to about 300 Torr. The polymer in the stabilization stage is maintained in the molten state at a temperature of from 160.degree. C. to about 220.degree. C. The polymer in the second devolatilization stage is maintained in the molten state at a temperature of from about 160.degree. C. to about 190.degree. C. and at a vapor space pressure of from about 0.1 to about 100 Torr.

Abstract: A process of making a full life size artificial rock formation of photocopy exactness from a natural rock formation surface is disclosed herein. A plurality of coats of latex is applied over the natural rock surface and allowed to dry thus forming a mask having all the natural cracks and crevices of the natural rock surface. This mask or liner is held in a fiberglass mold and a vacuum is applied to the inner surface of said liner causing all the cracks and crevices to open up. Cement is applied to the outer surface of the liner filling all the cracks and crevices. When the liner is removed the artificial surface resembles the natural rock surface in photocopy exactness.

Abstract: An improved method of forming a decorative panel of molded plastic comprising the steps of constructing a form having a detailed masonry surface; covering the detailed surface with a mold release material; applying a thin layer of gel coat over the mold release; applying a plurality of layers of fiberglass matte and resin over the gel coat layer; allowing the plurality of fiberglass matte and resin layers to harden thereby forming a heat resistant mold having a female side being formed against the detailed surface and a side opposite from the female side; removing the mold from the form; perforating the mold thereby providing fluid communication between the two sides; connecting a vacuum apparatus to the side opposite of the mold; placing a sheet of high impact plastic above and adjacent the female side of the mold; activating a heater thereby heating the plastic sheet to a pliable state; activating the vacuum apparatus thereby drawing the plastic sheet into the female side of the mold; and removing the forme

Abstract: An apparatus for impregnating porous samples for materials evaluation with an inert material which fills the pores of the samples. A plurality of samples are placed in mold cups on a rotatable table within a vacuum chamber, and a supply of impregnant or encapsulant material such as an epoxy resin is provided in a container mounted on a tiltable platform located above the rotatable table. A plurality of samples are thus mounted in respective molding cups spaced in a circle on the rotatable table, a supply of encapsulant material is provided in a cup placed in a cup holder on the tiltable platform, a vacuum is created within the chamber, and the table is intermittently rotated to position each molding cup with its sample in line with the tilt axis of the tiltable platform to permit tilting of the encapsulant cup to pour a supply of resin into the molding cup.

Abstract: A process of manufacturing a composite ski, particularly a laminated ski. The constituent parts of the ski are placed into an evacuable mold, which during or after its evacuation is supplied with a binder, which is preferably liquid and fills the pores of the constituent parts and the cavities between the constituent parts.

Abstract: A process of manufacturing a ski, particularly a laminated ski, which is composed of a plurality of components, and a ski manufactured by that process. In the process, the components of the ski are placed into a mold, which is adapted to be evacuated, and the mold is subsequently evacuated. A liquid binder, such as a liquid resin, is supplied to the mold during or after its evacuation. Air is sucked from the mold at one end of the longitudinal extent of the ski. The liquid binder is supplied to the mold at the other end of the longitudinal extent of the ski. In the finished ski a strip of solidified binder extends in at least one vertical or horizontal longitudinal plane of the ski, preferably in a central longitudinal plane of the ski, over at least part of the length and preferably over at least one half of the length of the ski.

Abstract: In a process for manufacturing a whisker preform for a composite material, a dispersion of a whisker in water or an organic solvent is passed through a sieve and is filtered, and a residual wet whisker cake is dried, with or without prior compression, to produce a cake having a desired density based upon the relationship between the weight of the whisker in the dispersion and the volume of the residual whisker cake after filtration.

Abstract: A method of compression molding powders of metals, ceramics and the like. A thin rubber bag is adhered to the inside of a cavity formed within a permeable mold support so as to define a mold therein and the bag is packed with a raw material powder. The powder in the bag is evacuated to a degree of vacuum to compactly compress it and the rubber bag is sealed. In this condition, the compressed powder is removed from the support and compression molded to a higher degree of denseness by the CIP process. The inflation adhesion of the rubber bag to the inside of the support cavity is effected by reducing the pressure outside the permeable support.

Abstract: A vacuum spinner chuck having improved holding power for thin wafers is obtained by providing a retention means for moveably holding an O-ring on the peripheral edge of the chuck. There is a first part-circular portion adjacent the upper surface of the chuck, arranged so that in the absence of vacuum the O-ring protrudes above the chuck surface and contacts the wafer. Below this first part-circular portion is a second sloped portion which tilts away from the surface of the spinner chuck by an angle preferably in the range 30-60 degrees. There is a smooth transition between these two portions. When vacuum is applied to the space between the wafer and the chuck, the wafer presses on the O-ring causing it to stretch and move down from the part-circular portion onto the sloped portion until the wafer rests on the surface of the chuck. The stretch creates an opposing force which holds the O-ring in contact with the wafer and the spinner chuck to prevent loss of vacuum.

Abstract: A thin-walled elastic envelope or mold element is arranged within a divisible outer supporting mold of porous material and a vacuum is applied to the outer supporting mold. Thereupon powdered metal or ceramic is introduced into the elastic mold element and the mold element is closed and pressurized to form a preform. The preform is then subjected to cold isostatic pressurization which is applied to the outer surface of the elastic mold element. Prior to the cold isostatic pressurization, the vacuum applied to the outer supporting mold is terminated and a vacuum is produced within the elastic mold element.

Abstract: A composition for the application of coatings on a substrate having a base of acrylic resin, comprising polymethylmethacrylate dissolved in a solvent composed of at least one ketone selected from methylethylketone and diacetone alcohol and of a chlorinated hydrocarbon selected from trichloroethylene and methylene chloride, the ratio of the volume of chlorinated hydrocarbon to the volume of ketone being at least 20 to 80.

Abstract: A device for monitoring the filling level of the degassing space in an extruder used for processing thermoplastic materials comprises a level detection orifice located in the degassing dome or jacket of the extruder which opening is connected to a conduit. The conduit leads through a regulator device to a gas source. Connected to the conduit, between the regulator device and the orifice, is a pressure sensor such as a pressure difference switch. If the level of molten material in the dome rises above a preselected level, it blocks the opening and produces a back-pressure in the conduit. The switch is automatically actuated by this back-pressure and produces a signal. Appropriate action can then be taken to prevent the further rise of the molten material in the dome and to prevent blockage of the degassing device.

Abstract: A method of making a glass laminated structure comprising retaining first and second glass panels against first and second platens respectively, using differential fluid pressure. The panels are held in spaced, generally parallel relationship and a curable flowable material is introduced into the space between the panels. The flowable material is then cured to provide the glass laminated structure.

Abstract: A molding mixture comprising a filler, such as wood particles and a resin binder, is pressed under light pressure on a flat bed to produce a mat with a density between 1/15 and 1/3 of the material in the finished article to be made by pressure molding. A molding preform is then made from a piece of such mat having a suitable contour, by sculpturing one side of the mat with suction devices to provide a thickness variation over the mat area corresponding to the requirements of the molding step.

Abstract: Epoxide compounds can be cured without resorting to the usual elevated temperatures by reducing the ambient pressure to 4.79 Pa or lower. This is particularly useful in potting circuitry.

Abstract: A method of manufacturing a thin-walled article of synthetic resin, in particular a large-sized article, while using an inner and an outer template, the synthetic resin being supplied via one or more apertures in one of the two template portions and whereby a partial vacuum is maintained via one or more air discharge apertures downstream of the synthetic resin front.

Abstract: A method of making a contoured cushion removably disposed on a recess defining support, with the cushion contour conforming to the shape of the portion of a person's body resting on the cushion.

Abstract: An RF probe and method for making same including laminating sheets of thermoplastic insulation to both sides of a layer of wire screen which is evacuated and pressure thereafter applied by fluid pressure acting on a diaphragm pressing member.

Abstract: In venting means for a screw extruder, particularly for thermo-plastics material, which venting means comprises a substantially vertical venting shaft communicating with the bore of a cylinder of the extruder and coupled to a low pressure source by a pipe, a pivotable flap which is moved from its normal position shown, when acted upon by plastics melt being extruded and rising in the shaft due to malfunction of the extruder, to cover the end of the pipe and prevent the melt passing into the pipe.

Abstract: The invention relates to metal casting employing a pattern in a sand mold. A thin film of translucent thermoplastic is coated with finely divided graphite and then superimposed on the pattern with the layer of graphite sandwiched in between. Infrared radiation is applied to the film to soften the same with the radiant heat which is absorbed by the graphite serving to speed up the softening process. Then while the film is in soft drawable condition the film is vacuum-formed onto the surface of the pattern with the graphite serving as a lubricant for the plastic film as the film is drawn about irregular or deeply indented surfaces on the pattern to produce a tightly conforming barrier layer. Sand is molded about the pattern and its barrier layer to form a mold, following which the pattern is withdrawn leaving the layer in conforming and supporting contact with the sand.

Abstract: In a method for producing large structural components such as boats or swimming pools of fiber reinforced synthetic materials layers of pre-impregnated fiber material are continuously applied to a mold. An air impermeable foil or membrane is sealed over the layers of pre-impregnated fiber material. The air is evacuated between the foil or membrane and the fiber material to press the latter by atmospheric pressure against the mold to cause the material to conform to the shear surfaces of the mold. The layers of pre-impregnated fiber materials are then heat cured by heated mats, for example, similar to electric blankets. The sheer surfaces of the molding apparatus are made of sheet material such as sheet metal or sheets of synthetic material. The pressure application and heat curing takes place sequentially in area after area whereby the final size of the finished structure is not limited by the size of an autoclave nor is it limited by the size of available heating blankets.

Abstract: A foam extrusion apparatus and method employs tandem extruders mounted on horizontal rails for movement toward and away from the end of a vacuum chamber which is in the form of an elongated inclined barometric leg. The upper end of the chamber is closed by a substantial bulkhead also supported on rails and held in inclined position to close the end of the chamber when moved thereagainst. A die is positioned on the inside of the bulkhead and aligned with the leg when closed. The extruders are connected to the die through a length of pipe supported through the bulkhead by a stainless steel bellows. The pipe externally of the bulkhead is provided with a circulating jacket for temperature control. The die is adjustable externally of the bulkhead. The extruders, die and bulkhead are movable as a unit or separately toward and away from the chamber to provide access to the die and the interior of the chamber.

Abstract: Thermoforming, utilized for making articles from sheets of thermoplastic ins, does not always yield articles having desired strength properties. It has been suggested that both thermoplastic and thermosetting layers be used to making the articles stronger. However it was virtually impossible to bond the layers together. A process is provided herein for obtaining that bond.

Abstract: A foam extrusion apparatus and method employs an extruder on an upper level extruding foamable extrudate into the upper end of a large elongated barometric leg which extends at a relatively shallow angle into a pool of water at a lower level. A conveyor in the barometric leg extends through a large radius in the pool to guide the extrudate from the pool for further processing. The leg is in the form of an elongated pipeline fabricated from sections and supported on an inclined ramp. Some of the sections are securely anchored to the ramp to resist axial forces when the leg is evacuated. The sections may be reinforced concrete or fabricated reinforced steel of a variety of sectional shapes. Each section is sealed end-to-end so that a vacuum within the leg will draw water from the pool into the leg leaving a vacuum chamber at the upper end of the leg in which the extrudate expands.

Abstract: A technique and process for clamping, sealing and aiding in the filling of fiberglass or other types of matched low pressure molds. An air-impervious bag is placed about the male and female molds and is sealed. A vacuum is then produced within the bag in such a manner as to fix the molds firmly together while sealing the mold parting line and whereupon a predetermined amount of molding material is injected within the mold cavity.

Abstract: A method is disclosed of molding a cementitious material within a mold having a filler material bed, the configuration of which is maintained by means of suction applied through a filter disposed within the mold frame. A shield layer can be formed upon a surface of the filler material bed having air permeability so as to impart a desirable shape thereto, and the filler material is fixed under reduced pressure conditions within the mold so as to form a molding mold, whereupon the cementitious material may be charged into the mold so as to set therein. It is also possible to achieve the method of the present invention by charging a cementitious material within a molding mold having a desirable configuration, forming a filler material bed having good air permeability with or without a shield layer disposed upon the cementitious material, and preparing a hardening mold, under reduced pressure conditions, beneath the filler material bed.

Abstract: This disclosure relates to a method of retreading a tire by inserting a tire and an annular bladder between a pair of open matrices with marginal portions of the bladder projecting beyond beads of the tire and resting upon peripheral edge portions of axially opposed bead aligner wheels; the annular bladder being disposed within the tire; inflating the bladder to form an annular gap sealed between an annular terminal edge of each bladder marginal portion, an annular outboard portion of each bladder and opposing annular portions of the bead aligner wheel peripheral edge portions; closing the matrices, and further inflating the bladder to urge the tire into intimate conformity with the matrices.

Abstract: A method and apparatus is provided for the manufacture of products of concrete or like construction, in which a mixture of calcareous cementitious binder substance, such as cement, an aggregate, a vinyl acetate-dibutyl maleate copolymer, and an amount of water sufficient to make a relatively dry mix is compressed into the desired configuration in a mold, and with the mixture being exposed to carbon dioxide gas in the mold, prior to the compression taking place, such that the carbon dioxide gas reacts with the ingredients to provide a hardened product in an accelerated state of cure having excellent physical properties.

Abstract: Cellular lightweight concrete slabs are manufactured by cutting horizontally through a block of still plastic cellular concrete mass resting on a support. At each cut a single slice is separated from the lowermost portion of the block or the remainder thereof. After each completed cut the upper remainder of the block is elevated by means of a suction head, in order to expose the recently cut surfaces for a treatment, and then again deposited on top of the slice or slices already resting on the support. Rotary roller means are provided for contributing in the surface treatment.

Abstract: Cellular lightweight concrete slabs are manufactured by cutting a still plastic block of cellular concrete mass resting on a first support horizontally into slices which are then moved over one by one to a second support and piled in reversed order thereon, at least one of the two broadsides of each body slice being subjected to a treatment before being covered by the next transferred slice. The treatment prevents the body slices from cementing together during the subsequent steam-hardening process and may also improve the quality of the slabs when hardened. An apparatus for such manufacture features a movable suction head for transferring the body slices as well as associated means for cutting and treating said slices.

Abstract: Fiber reinforced plastic structural components having curved surface areas are produced in molds utilizing a bleeder cloth comprising a textile-like non-woven polyester fabric characterized by a fiber interlock value of at least 7 and a fiber entanglement completeness of at least 0.5. The utilization of this bleeder cloth allows quicker assembly of the mold components since cutting and forming are not necessary, proper pressure transmittal is ensured, and the air permeability, drape, stretchability, and resin holding capacity of the cloth are ideal. For producing the desired structural components with curved surface areas, at least one layer of resin pre-impregnated partially cured fabric is disposed in cooperation with a first mold section, a release liner is placed on the fabric, and a bleeder cloth according to the invention is placed on the release liner.

Abstract: A method of casting liquid compositions in elastomeric molds wherein the casting composition has a reaction temperature below about 235.degree. F comprising:A. introducing an organic solvent soluble polyol, a liquid polyisocyanate and a basic curing catalyst having a pK.sub.b value from between 7 and about 11 into an open elastomeric mold,B. controlling the ratio of polyol to polyisocyanate and the concentration of the curing catalyst and casting the resin such that the cured resin is: substantially free from entrapped air at the mold surface, free from foaming, has a cast time of generally less than about 15 minutes, has a tensile strength of at least about 2500 psi,C. removing the cast resin from the mold shortly after the composition is cast thereby providing unexpected prolonged mold life. The resin undergoes substantially no change in volume from the liquid to the cured state.

Abstract: A textile material is molded by preheating to its transition temperature and then rapidly deformed by stretching without cooling. The deformation is maintained for a certain time at the preheating temperature or higher. The material is then quickly cooled. An apparatus for molding particularly fabric has a heat chamber having an opening over which the fabric is fastened, and a molding body having the desired shape and movable towards the heat chamber so as to stretch the fabric while entering partly through the opening. The molding body and heat chamber can be heated and the heat chamber may be evacuated or supplied with air under pressure for cooling the fabric.

Abstract: Hydraulic cement or the like is poured into a closed mould under a reduced pressure condition to a level slightly higher than a predetermined level. Coarse aggregate and steel rods are prepacked in the mould. After pouring the pressure in the mould is increased to atmospheric pressure or a higher pressure to force the hydraulic cement above the predetermined level back into the space below the level thus compacting the poured in hydraulic cement. A cushion device is provided for the pouring device. An overflow tank is connected to the mould to observe the level of the poured cement. The pressure in the overflow tank is also decreased during pouring and increased after pouring.

Abstract: This invention relates to a method of making fabric-faced upholstered items. The items are made by vacuum forming under heat a laminate of a cast highly plasticized vinyl chloride homopolymer or copolymer sheet and a readily extensible fabric, and the resulting shaped cover is filled with a foam which is foamed in situ, the foam bonding to the thermoplastics sheet of the laminate and holding the laminate in shape. The laminate must have an extensibility in two directions at right angles of at least 25% under a load of 51b per 2 inch wide strip when subjected to loads of 51b applied at right angles to one another to the edges of a 2 inch side square of the fabric, and be capable of increasing its surface area by at least 50%. The fabric can have this high degree of extensibility and still be suitable as a cover because the laminate is bonded to the foam filling and so held to shape.

Abstract: The present invention relates to plastic extruded strapping and its processing techniques. More particularly, it is concerned with polyester extruded strapping of high tensile strength and low elongation at break to replace steel strapping. Although not limited thereto, this invention is of primary importance in connection with the technique of crystallization and orientation of polyester predominantly in one direction in the making of strap characterized by two-step stretching. Furthermore, this invention is related to the design of a multi-purpose extrusion line for the processing of strap of various polymeric materials.

Abstract: In an injection moulding process for forming hollow preforms on a mandrel which is subsequently used as a blowing pin for blowing the preforms to the final shape in a blow mould separation of the preform from the mandrel during cooling of the preform from the injection temperature is prevented by applying a vacuum to the blowing channel in the mandrel before the injection pressure is released.

Abstract: A method of fabricating a reinforced plastic tubular article. A mandrel is positioned within a mold in spaced relation to the inner surface of the mold. Dry reinforcing material, in the form of fibrous or particulate material or a combination of both, is located in the annular space between the mandrel and the mold. The interior of the mold is evacuated to remove gas from the mold as well as from the voids within the reinforcing material. An uncured thermosetting resin system, which was mixed under vacuum conditions to remove gas from the system, is introduced into the mold. Pressure is applied to the resin to thoroughly impregnate the reinforcing material with the resin. The resin is then cured by heating while the pressure is maintained on the resin. The resulting cured product has a smooth outer surface which facilitates the attachment of coupling members and has improved mechanical properties.

Abstract: A molding process for casting operations in which castings having a deep concave portion or a high convex portion such as pots and bathtubs are cast using vacuum sealed molds on which films are applied to be in tight contact with them, and a film forming auxiliary device for use in molding such vacuum sealed molds.

Abstract: This invention is a method of making blown plastic articles on an injection blow molding machine with an expandible balloon that covers the core rods and over which a parison is applied at an injection mold station. The parison can be blown at lower temperatures for better orientation; and the balloon permits circulation of cooling fluid, including liquid, to cool the blown article from the inside while contact with the blow mold cavity cools the blown article from the outside.