Abstract: A manufacturing system and method for use in the production of high strength plastic materials which can be used in the construction arts. The system and method includes a central rotary mold element which has vacuum means and cooling means placed inside thereof. Heating elements are positioned exteriorly of the rotary mold. Treated long fiber sheets are introduced to the rotary mold and combined with plastic sheets which are also fed to the mold.

Abstract: A manufacturing system and method for use in the production of high strength plastic materials which can be used in the construction arts. The system and method includes a central rotary mold element which has vacuum means and cooling means placed inside thereof. Heating elements are positioned exteriorly of the rotary mold. Treated long fiber sheets are introduced to the rotary mold and combined with plastic sheets which are also fed to the mold.

Abstract: A method and apparatus for making an imprinted conductive circuit using semi-additive plating. A plurality of indented channels is formed on the substrate. The surface is coated with a conductive layer. Portions of the surface other than the indented channels are coated with a non-conductive layer, and metal is plated on the conductive layer in the channels. The non-conductive layer and the first conductive layer are removed from portions of the surface other than the indented channels. In some embodiments, a first set of channels has a first depth and a second set of channels has a second depth. The plating adds a first amount of metal in the first set of channels and the second set of channels. The first set of channels is coated with a non-conductive layer, and a second amount of additional conductive material is plated in the second set of channels.

Abstract: Methods for making a tubular device that has a rim disposed at one end thereof. In one method, a sleeve having an expandable profiling surface is inserted into an end of the tubular member, and the profiling surface is expanded to form a shoulder projecting outwardly from the tubular member adjacent the end of the tubular member. The profiling surface is collapsed inwardly away from tubular member, and a return margin is formed directed inwardly from the shoulder, distal the tubular member. In another method, return margin of the tubular device adjacent an end is folded inwardly and superposed on an inner surface of the tubular device adjacent the folded margin. A sleeve having an expandable profiling surface is inserted into the end of the tubular device, and the profiling surface is expanded to form the rim comprising a shoulder projecting outwardly from the tubular member and the return margin. As a result, the fold between the shoulder and the return margin defines an edge of the tubular member.

Abstract: A method and apparatus for making multiple layer optical discs is applied to separate the base plate from the mold plate. The apparatus includes a first adhesive ending groove, a mold plate, a sealing member and an air-blowing axle. The adhesive does not cover the area around the first and second openings and the first and second adhesive ending grooves, so an enclosed cavity is formed between the first and second openings. The air-blowing axle passes through the second opening and encloses the cavity but leaves injestion ports in the cavity so that air can be injected into the cavity for separating the base plate and the mold plate while the second recording layer and the adhesive layer adhere to the base plate.

Abstract: A method of forming a curved hose and a mandrel for forming a curved hose is disclosed. A hose length is inserted onto a multi-legged mandrel to form a curved hose. The mandrel has at least two legs and the opposing ends of the hose are placed on the mandrel legs such that a portion of the hose is unsupported by an internal mandrel. The unsupported portion of the hose may be straight or may be looped to form a more complexly curved hose. The unsupported portion of the hose may also be held in position by an external mandrel.

Abstract: The invention relates to a picking-up device and assembly for making a part made of a reinforced plastics material in a mold. The picking-up device includes at least one presser having a shaped front face and first needles mounted to have end portions that project beyond the front face in one position and retract so as to be set back from the front face in a second position. The picking-up device may have a base mounted to move relative to the picking-up device. A production line may be formed from use of two picking-up devices.

Abstract: The invention relates to a matrix suitable for use in the replication of a plastic element having a positive microstructure, comprising a first wear-resistant layer that is supported by a carrier element, wherein the matrix comprises a heating means for supplying electrical heat energy through the wear-resistant layer or carrier element. The invention further relates to a plastic element producing machine and a method for the manufacture of a plastic element having a surface with a positive microstructure.

Abstract: A method of making a catheter balloon or other tubular medical device or component, in which a sheet of polymeric material is wrapped on a mandrel and heated to fuse sections of the wrapped sheet together to form a tube. The mandrel has a metallic core and a jacket on an outer surface of the metallic core, and the wrapped sheet of polymeric material is heated without corroding the metallic core of the mandrel. In a presently preferred embodiment, the sheet is formed of a fluoropolymeric material, and the resulting fluoropolymeric tube forms at least a layer of a catheter balloon.

Abstract: The invention is directed to adjustable length mold assemblies for forming inflatable members and methods for using adjustable length mold assemblies for forming inflatable members, such as, for example, balloons for use with balloon catheters and stent delivery systems. The adjustable length mold assemblies comprise at least two mold pieces adapted to fit together, one mold piece having a surface configured to be slidably received by a bore of the other mold piece, the placement of one piece within the other defining a chamber of variable length which forms the mold. Each adjustable length mold assembly of the present invention is effective to form balloons, where if desired different balloons formed by a single mold may have different lengths. The adjustable length mold assemblies may also comprise a positioner to put a mold piece in a desired position relative to the other, and a locking mechanism to secure a mold piece in a desired position.

Abstract: A flexible or semi-rigid support fixture is sized and shaped to supportably engage a surface of a polymeric matrix object such as an organic bonded abrasive grinding wheel. The support fixture is utilized to support the object to help prevent slumping and/or expansion during thermal curing operations. The fixture is fabricated from a material, such as silicone rubber, that is capable of withstanding heat commonly associated with thermal curing operations and which provides sufficient resilience to permit use with objects manufactured within a relatively wide range of dimensional tolerances. Suitable materials include silicone rubber or other polymers or copolymers such as PTFE, FEP, Polyimide or blends with or without fillers or substrates.

Abstract: A connector element for connecting frame parts at a joint location in a bicycle frame is made of a single part of structural fiber based material, typically carbon fiber material, after reticulation in a mould exploiting the expansion of a core on which windings of fiber fabric material are provided, to obtain the application of a uniform radial pressure on the layers of fiber based material. In one embodiment, the connector element defines a bicycle bottom bracket and tubular extensions departing therefrom for connection to elements of the bicycle frame.

Abstract: A female mold vacuum forming apparatus and a method for using the female mold vacuum forming apparatus for providing improved draw depth capability. The female mold vacuum forming apparatus comprises a top contoured surface and a cavity having a cavity surface formed within the top contoured surface. The cavity surface defines part geometry having deep-draw sections. The top contoured surface defines open sections in the side surfaces of the mold adjacent to at least one deep-draw section to allow free formation of parts within said at least one deep-draw section.

Abstract: An apparatus for repairing or refurbishing thermoplastic drums. A damaged drum, or at least a damaged portion thereof, is heated until it reaches a softened state and is then drawn over a template, or mold, having the substantially the same shape and size of an undamaged drum. The drum is allowed to cool sufficiently to return to its hardened state, whereby it substantially assumes the shape of the template. The refurbished drum is then removed from the template and is essentially ready to be used again.

Abstract: A heat source is formed within one piece of a multi-piece mold designed to shape a glass tube. The one piece of the mold can then be used as a source of intense heat to render the glass malleable and to also contribute to shaping the tube in conformance with the mold. In one embodiment, the heat source includes channels formed throughout the one piece of mold for distributing a gas therethrough with jets of gas emanating from the inner surface of the mold piece for heating the tube to be shaped to a desired temperature. In apparatus embodying the invention, there is no need for a separate torch and for moving the torch during the shaping process. Also, in accordance with the invention, better control of the heat supplied to the tube being shaped is obtained.

Abstract: A forming tool with one or more embossing tooth, and preferably, a plurality of such embossing teeth, arranged on a substantially planar substrate, is disclosed. Each embossing tooth is configured for forming a sacrificial layer to provide a contoured surface for forming a microelectronic spring structure. Each embossing tooth has a protruding area corresponding to a base of a microelectronic spring, and a sloped portion corresponding to a beam contour of a microelectronic spring. Numerous methods for making a forming tool are also disclosed. The methods include a material removal method, a molding method, a repetitive-stamping method, tang-bending methods, and segment-assembly methods.

Abstract: A method and method to ensure the uniform collapse and diminished loading forces of a prosthesis, the prosthesis having at least one layer of biocompatible material. The device includes a way to stabilize the prosthesis, wherein the prosthesis can be incrementally axially rotated, and a way to manipulate the layer of biocompatible material simultaneously at several distinct points along an axis of the prosthesis so that a set of alterations is formed in the biocompatible layer.

Abstract: A method of treating a power transmission belt/belt sleeve of the type having an endless body with a length extending around an axis and a radially inwardly facing surface and a radially outwardly facing surface. The method includes the steps of wrapping at least one sheet of vapor-impervious film against and around the radially outwardly facing surface of the belt/belt sleeve body and vulcanizing the belt/belt sleeve with the at least one sheet of vapor-impervious film wrapped around the belt/belt sleeve body.

Abstract: A flexible or semi-rigid support fixture is sized and shaped to supportably engage a surface of a polymeric matrix object such as an organic bonded abrasive grinding wheel. The support fixture is utilized to support the object to help prevent slumping and/or expansion during thermal curing operations. The fixture is fabricated from a material, such as silicone rubber, that is capable of withstanding heat commonly associated with thermal curing operations and which provides sufficient resilience to permit use with objects manufactured within a relatively wide range of dimensional tolerances. Suitable materials include silicone rubber or other polymers or copolymers such as PTFE, FEP, Polyimide or blends with or without fillers or substrates.

Abstract: A thermal pressure die for pressing and heating a trim cover assembly for automotive seat into a desired uneven configuration, the trim cover assembly having a decoratively finished outer surface with aesthetic solid or projecting decorative patterns defined thereon. A protection element of elastic and heat insulation property is provided on an uneven die surface of the die which is to be brought into pressing contact with such decoratively finished outer surface of trim cover assembly. Hence, the solid or projecting decorative patterns on the trim cover assembly outer surface are protected by the protection element against any deformation due to pressure and heating generated in the thermal pressure die.

Abstract: A method and apparatus for repairing or refurbishing thermoplastic drums, by which a damaged drum, or at least a damaged portion thereof, is heated until it reaches a softened state and is then drawn over a template, or mold, having the substantially the same shape and size of an undamaged drum. The drum is allowed to cool sufficiently to return to its hardened state, whereby it substantially assumes the shape of the template. The refurbished drum is then removed from the template and is essentially ready to be used again.

Abstract: Disclosed is a cap for use in manufacturing a curved hose on a mandrel. The cap is a cylinder with a wall, a base, and an opening. The cap has an open groove in the wall extending from the opening towards the base. A mandrel with a curve located near the end of the mandrel is inserted into the cap, the mandrel projecting from the cap groove. The cap enables the manufacture of a curved hose with a short straight end adjacent to a curve.

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 customizable skirt-forming member is disclosed, for use in high stress acrylic tub formation operations. The member generally has a rigid forming wall, at least one adjustable wing hingeably associated with the forming wall, and means for altering the pitch of the at least one wing, relative to the sidewall, so as to simultaneously alter a hinge angle therebetween. The member allows for customized, angled formed front tubs to be formed, while ensuring that the stresses of system operation do not alter the intended angles.

Abstract: A substrate having a photoresist coated thereon is exposed to exposure light along a line through a lens 1. The exposure position is moved from the initial position O1 to a position O2 that is separated from the initial position by a distance corresponding to the sum of a groove width Gw and a land width Lw. The exposure is carried out along a line parallel to the initial exposure line. By repeating this, exposed areas having a width Lw and a separation Gw are formed on the photoresist. The photoresist is developed to remove the exposed areas of the photoresist. A resin or the like is pressed on it to form a replica. From the replica, a stamper is manufactured using an electroforming method. Finally, a grooved molding substrate is manufactured from a glass or resin using the stamper. Although the land width Lw is defined by the effective spot diameter &phgr; of the optical system, the groove width Gw can be less than this value.

Abstract: Apparatus for molding an annular article, such as a radiator hose, from an organic material, such as an elastomeric material, the apparatus having a mandrel with an external surface against which an inner surface of the article is molded. The mandrel also has an end extension of reduced radial extent and an end cap is releaseably secured to the extension to provide a generally transversely extending annular surface against which an end of the article is molded. The end cap has a passage extending therethrough at a location adjacent to an adjacent portion of the extension and in a plane extending generally transversely to a longitudinal centerline of the article, and the shank of a generally J-shaped locking member is slidably inserted in the passage. The locking member is resiliently biased towards a position where a portion of the locking member disengageably engages an annular recess in the extension to lock the end cap in position relative to the extension.

Abstract: A fine pattern of an optical device formed by the Photo-Polymer method has a groove 100, a side wall 100a of which is sloped against a surface of stamper 18. The slope angle &thgr; of the side wall 100a satisfies the following relational expression: Tan−1 (4×h×w1−0. 2)<&thgr;<80° where h: a depth of the groove 100; and w1: a width of a top of a projected portion formed by the side walls 100a. Burrs formed in the optical device are reduced, and thereby mass productivity of the optical device is improved.

Abstract: A stamp for forming customized designs and decorative edging in concrete surfaces of varying size and shape. The stamp has a smooth contact surface and a ridge that defines a pattern that is imprinted in sufficiently hardened concrete. The tool also has measurement markings and reference points that can be used for positioning the tool in a desired location. The stamp has the property of being able to be placed adjacent to another tool or imprint that is out of horizontal and vertical alignment without interfering with the adjacent tool or imprint. The stamp also has the property of being able to overlap a previous stamp placement without interfering with the imprint formed by the previous stamp placement.

Abstract: A process for forming molded articles from particulate thermoplastic material, the process comprising: (a) providing a track having a plurality of process stations, (b) providing a mold assembly comprising a base, at least one hollow mold upstanding from the base, and guide means on the base for moving the mold assembly on the track, (c) preheating the mold assembly at a preheat station on the track, (d) moving the mold assembly from the preheat station to a transfer station on the track, (e) transferring the mold assembly from the transfer station to a molding station, (f) forming the molded articles by fusing particulate material to the at least one mold at the molding station, (g) transferring the mold assembly with the molded articles thereon from the molding station back to the transfer station, (h) moving the mold assembly from the transfer station to a cooling station on the track, (i) moving the mold assembly from the cooling station to an unloading station on the track, (j) removing the mol

Abstract: A process for manufacturing an air flow assembly having a valve disc within a bore. A first support is inserted into the bore from below the valve disc, and a second “floating” support is inserted from above the disc. The second support “floats” relative to the disc upon a fluid receiving member such as an inflatable bellows. As the fluid receiving member allows the second support to float when contacting the disc, any inconstancies of the disc are compensated by the “floating” second support. As the disc is squeezed between the supports heat conducted from heaters causes the material of the disc to be extruded radially outwardly into contact with the bore to obtain a consistent thickness at the disc outer periphery.

Abstract: The invention is directed to modular molds for forming an inflatable member, in particular, balloons for use with balloon catheters and stent delivery systems. The detachable molds of the present invention include detachable segments including a generally cylindrical intermediate segment having an intermediate longitudinal dimension and an intermediate interior chamber with an intermediate inner diameter, and proximal and distal segments longitudinally disposed at opposing ends of the intermediate segment and having corresponding interior chambers.

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 mold for shaping the end region and the opening at a selected end of a first, hollow, generally cylindrical, glass tube to enable a second tube, of smaller diameter than the first tube, to be inserted snuggly a first distance within the selected end of the first tube resulting in the two tubes nesting and being self-centered. The mold includes two complementary elongated side pieces having inner side surfaces for, when joined, encircling the periphery of the first tube along a given portion of its selected end region, and an end cap with a cylindrical stub for insertion within the opening of the first tube at its selected end.

Abstract: A green ceramic core or other article at elevated temperature is placed between a complaint member and a relatively rigid setter while the green core or article cools to a lower temperature. The compliant member can comprise a fluid pressurized compliant bladder or a compliant, non-rigid setter or facing layer thereon for contacting a side of the green core or article.

Abstract: A forming track forms flexible plastic tubing which carries fuel from a fuel tank to an engine into a desired shape. The forming track includes a curved channel to receive a round tubing and a pair of opposing flanges to secure the tubing in the forming track. The tubing slightly deforms between the pair of opposing flanges as the plastic tubing is positioned in the channel. After the tubing is inserted, the opposing flanges secure the tubing in the forming track. While positioned in the forming track, the tubing is set by heating and rapid cooling, thermosetting the tube into the shape of the forming track.

Abstract: The present invention relates to specific methods of producing cleated rubber-backed floor mats (such as dust control or rubber mats) through the utilization of the combination of a perforated coated woven fabric article and a cushioned platen liner between the article and the metal platen of an in-line dust control mat manufacturing machine. Such a procedure permits a more efficient manner of producing cleated anti-creep dust control mats than previously followed. In particular, the fabric article is in the form of a conveyor belt and is preferably constructed from Teflon®-coated woven fiberglass which will not adhere to the tacky rubber component of the target mat and can withstand the extremely high vulcanization temperatures and pressures required during the production of a dust control mat.

Abstract: This invention relates to a splittable medical device incorporating two sets of preferential tear lines. The first set of preferential tear lines preferably includes two longitudinally extending skives formed along the exterior surface of the proximal portion of the splittable medical device. The second set of preferential tear lines preferably includes a plurality of grooves formed along a distal portion of the interior portion of the splittable medical device. The skives should be substantially aligned with some of the grooves. This configuration facilitates splitting of the medical device along the skives and along one or more of the grooves to allow a clinician to split the medical device completely into two pieces. This invention includes a special mandrel having a plurality of ribs formed along a distal portion thereof and process that is used to manufacture the splittable medical device.

Abstract: The present invention comprises a method and apparatus for repairing or refurbishing thermoplastic drums, by which a damaged drum, or at least a damaged portion thereof, is heated until it reaches a softened state and is then drawn over a template, or mold, having the substantially the same shape and size of an undamaged barrel. The drum is allowed to cool sufficiently to return to its hardened state, whereby it substantially assumes the shape of the template. The refurbished drum is then removed from the template and is essentially ready to be used again.

Abstract: The present invention provides an improved syntactic foam plug for plug assist thermoforming wherein such plug is composed of a thermoplastic material having a relatively high melting and/or glass transition temperature. Accordingly, the subject invention encompasses diminishing or removing the undesirable characteristics of thermoset syntactic plugs while increasing the ease by which these articles may be constructed for a given use, by forming such plugs from syntactic foams containing thermoplastics.

Abstract: A stamper for forming a data recording region on a recording medium substrate by means of a transfer surface thereof. The transfer surface transfers a predetermined set of data to the recording medium substrate. The stamper is fitted on at least one of metal molds that are arranged opposite one another for forming the recording medium substrate. The stamper includes a stepped portion formed as bends in the material of the stamper. The stepped portion is configured to project from the transfer surface toward the recording medium substrate.

Abstract: A method and apparatus for producing a composite component having a variable thickness includes placing a caul member over a plurality of laid-up prepreg plies supported by a mold and curing the lay-up in an autoclave. The mold includes a cavity for receiving the lay-up that is defined by a bottom surface, a plurality of walls extending upwardly from the bottom surface, and an open upper face surrounded by a mold edge. A support flange extends inwardly toward the center of the cavity from each of the walls at a predetermined distance upward from the bottom surface. The predetermined distance varies along the length of the mold and generally conforms to the outer profile of the composite component to be fabricated. The caul is positioned over the lay-up and defines a longitudinal axis extending along the length of the caul and a lateral axis extending along the width of the caul.

Abstract: The invention relates to a method of producing a matrix suitable for use in a plastic element-producing machine, a matrix produced in accordance with the method and use of such a matrix to form a plastic element. One side of the matrix is provided with a negative microstructure which is replicated in plastic material to form a positive microstructure on a plastic element, wherewith the matrix can be produced by applying a layer of material to the positive microstructure side of a master. The positive microstructure side of the master has a thin wear-resistant layer which serves as a first wear surface, wherewith said layer will present irregularities which correspond essentially to the microstructure, and wherein at least said irregularities are filled-in with a plastic composite so as to form a carrier element for supporting the first wear layer. The layer can further be provided with means for supplying heat energy to said matrix.

Abstract: A light guiding plate is manufactured with accuracy and at low cost. This invention comprises a cylindrical roller, which has a heater built-in, rotating while fixing a stamper having a dot pattern formed on its surface, substrate fixing means for reciprocating along a lower portion of the cylindrical roller in accordance with rotation of the cylindrical roller as fixing a resin substrate, and pressing means for pressing the stamper, which is fixed to the cylindrical roller, onto a surface of the resin substrate, which is fixed to the substrate fixing means, with a constant pressure.

Abstract: The invention is directed to adjustable length mold assemblies for forming inflatable members and methods for using adjustable length mold assemblies for forming inflatable members, such as, for example, balloons for use with balloon catheters and stent delivery systems. The adjustable length mold assemblies comprise at least two mold pieces adapted to fit together, one mold piece having a surface configured to be slidably received by a bore of the other mold piece, the placement of one piece within the other defining a chamber of variable length which forms the mold. Each adjustable length mold assembly of the present invention is effective to form balloons, where if desired different balloons formed by a single mold may have different lengths. The adjustable length mold assemblies may also comprise a positioner to put a mold piece in a desired position relative to the other, and a locking mechanism to secure a mold piece in a desired position.

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 and includes an edge for delaying tearing of the elastomeric coating. Good release of the detergent bars from the die is possible without chilling of the dies. Use of the edge increases the useful life of the coating.

Abstract: A flexible tool that fits over the pressure or concave side of a metallic airfoil that includes a lightweight material component for a gas turbine engine during the fabrication of the airfoil. The metallic fan airfoil includes pockets or cavities that have been machined into the airfoil in order to reduce the weight of the airfoil. The tool is a flexible body manufactured from sheets of composite material and includes an integral elastomeric seal. The tool is placed over the airfoil and forms a seal against the pressure side of the airfoil so that lightweight resin can be injected into the pockets and retained in position during curing. The flexible tool is formed by laying up thin sheets of composite material that includes fiber over a metallic master tool after partially cured elastomeric material is placed inside a marking corresponding to the airfoil perimeter.

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.

Abstract: A mold assembly for press molding plastic material into products under heat and pressure wherein the material is placed on a base mold having at least one or more guide blocks spaced thereabout for accommodation of wedge mold segments each having a surface matched to a portion of the base mold. Each wedge mold segment is arranged to move over an inclined surface of a guide block into compression mated association with material to be molded on the respective portion of the mold base to which it is matched. In operation the wedges are pushed downward by a press and moved laterally over the stationary inclined surfaces of the guide blocks which guide the wedges inwardly in matched pressure relation with the material to be molded on the sides of the base mold. The invention also includes division of the wedge mold segment into an assembly of two parts in which a mold section is backed by an associated wedge member which pushes the mold section into molding position.

Abstract: A recess of a thermoplastic resin container is formed by urging a part of a thermoplastic resin sheet into a cavity of a mold after heating the part of the thermoplastic resin sheet, so that a bottom portion and side walls of the recess are formed, wherein a bottom of the cavity has a convex shape area protruding in a depth direction away from the base portion formed on another part of the thermoplastic resin on the mold.

Abstract: A press die composed of an upper die having a concave part (with the peripheral surface of the opening of said concave part functioning as a first blank pressing face), a lower die having a convex part (to form the blank into a desired form in cooperation with said concave part), and a blank holder (which has a second blank pressing face), said press die working in such a way that said first blank pressing face and said second blank pressing face hold a blank between them while permitting it to flow into said concave part during pressing, characterized in that at least either of said first blank pressing face and said second blank pressing face has a roughened surface with a plurality of striated projections which are formed in the direction inclined in a range of −25° to +25° (preferably approximately parallel) toward the circumferential direction of the edge of the opening of said concave part.