Abstract: A method of diametrally expanding an elastic tube (6), which includes the steps of inserting a distal end portion of a expansion member (1) into an elastic tube (6), the expansion member (1) being provided at least at a surface thereof with a solidified layer of a low melting point material, and the distal end portion (4) of the expansion member (1) being tapered, a tip end of which having a diameter which is equal to or smaller than an inner diameter of the elastic tube (6), and moving the elastic tube (6) over the solidified layer to diametrally expand the elastic tube (6), the surface of the solidified layer being made into a low frictional surface due to a melting of the low melting point material.

Abstract: A method of manufacturing a golf club head that includes a peripheral shell constituted by an assembly of walls obtained by injecting a plastic material forming an inner cavity enclosing at least one inner insert kept immobilized by a partial plastic material coating of the shell. Prior to the injection step of the shell, an assembly is placed and immobilized in the mold which is comprised of a meltable core made of a second material having a melting point that is lower than the melting point of the plastic material in the space left free between the walls of the mold and the assembly, so as to coat the meltable core and all or a part of the free portion of the insert. Finally, all or a portion of the meltable core is eliminated to enable an inner volume to be freed so as to form the inner cavity.

Abstract: A load bearing structure having a set of uniform voids functions to resolve the forces imposed by developing compression in the material having the voids and minimizing the amount of tension developed in the material. The voids are deployed to encompass a matrix of points arranged such that each point is spaced an equal distance from twelve and only twelve adjacent matrix points. If the structure is considered to be composed of a closely packed set of hypothetical rhombic dodecahedra (RD) and the four-edge vertices of each of those hypothetical RDs is truncated, the result will be a set of cubic voids. The center of each of those cubic voids will define the matrix referred to above and the cubic voids will serve to provide the optimum resolution of stress which minimizes the development of tension in the material. One in four of the hypothetical RDs can be eliminated achieving the same force resolution in a structure containing less material.

Abstract: A mold assembly and sprue configuration for dental investment casting includes a ring shaped casing, a base and a cover all made of resilient plastic material and fictionally engaged with each other. The base includes a raised neck having a top surface with a sighting bead for use in mounting wax forms on the sprue, positioned within the casing. The sprue includes a post for engaging a blind bore in a hub of the base. The cover includes a downwardly extending plug which extends into the body of the casing, and a curved lip with recess for facilitating the pouring of investment solution into the mold. The sprue has three spokes and a ring which are all triangular in cross-section to reduce the amount of metal needed in the precision casting to be made with the invention and also to provide a convenient flat upper surface for mounting wax forms to the sprue.

Abstract: A method making an affixation member including a body for affixation to a surface of a structure and means for fastening the body to the surface. The fastening means including an interengaging fastener member which has a base secured to the body and a plurality of headed stems arranged on the base. The fastening means is formed by flowing molten material into a base mold, a destructible stem mold and a head mold. The base mold and head mold are separated, and the destructible stem mold and the molded interengaging fastener member are placed within a cavity of a body mold. An affixation member fixedly supporting the interengaging fastener member is molded in the cavity of the body mold. The body mold is separated from the molded affixation member, and the stem mold is destructibly removed from the interengaging fastener member fixedly supported on the molded affixation member.

Abstract: A load bearing structure having a set of uniform voids functions to resolve the forces imposed by developing compression in the material having the voids and minimizing the amount of tension developed in the material. For the voids to have this function, they must be deployed in a particular fashion. The voids are deployed to encompass a particular set of points. The set of points are such that each point in the matrix is spaced an equal distance from twelve and only twelve adjacent points of the matrix. The distance between the points does not matter as long as all are uniformly distanced in accordance with that rule. If the structure is considered to be composed of a closely packed set of hypothetical rhombic dodecahedra (RD) and the four edge vertices of each of those hypothetical RDs is truncated, the result will be a set of cubic voids.

Abstract: The present invention relates to an apparatus for forming a fastener member having a base and a plurality of headed stems arranged in columns and rows and projecting from the base. The fastener member is formed by injection molding a molten material into a base mold, sacrificial stem mold and head mold, wherein the material is solidified. After the base mold and head mold are removed, the stem mold may be removed to release the fastener member.

Abstract: A core ring assembly for use in production of a plastic injection-molded component is formed by injecting molten metal alloy into core dies to produce two intricately shaped ring type elements--one male, one female. Removing the male and female ring elements from the core dies and combining the two elements in an assembly machine to form a uniform, geometrically symmetrical, integral core ring assembly. The core ring assembly is transported to a plastic molding machine for overmolding the core ring assembly with either thermosetting or thermoplastic material. Then, the core assembly is melted out from the plastic component in a hot oil bath or induction melt-out, and the molten alloy recovered thereby is returned to a molten metal alloy tank for reuse.

Abstract: A molded article is prepared by forming a glass core, treating the glass core to induce residual stresses therein, inserting the core into a mold, injecting resin into the mold, curing the resin, fracturing the core to produce glass particles, and removing the glass particles from the molded article.

Abstract: An apparatus for molding experimental, prototype and replacement parts from rubber materials. The apparatus consists of a mold having walls made from layers of fiberglass cloth and laminating resin reinforced with a mixture of quartz sand and laminating resin; a frangible cellular core made of a two component system polyurethane foam core and a hard outer coating of a quick set resin; a wax; and a release agent. The frangible core is formed by coating the surfaces of a core forming cavity of a core box with the wax to fill in irregularities; buffing the wax coating to provide a smooth finish; applying the release agent over the wax; coating the release agent with the hard quick set resin; and filling the core forming cavity with the two component system polyurethane foam. The frangible core is inserted in the mold, a rubber polymer is injected into the mold and the frangible core is removed from the part by breaking the core into small pieces after the part is removed from the mold.

Abstract: A device for injection moulding plastic articles by the fusible-core technique includes a unit (1) for moulding fusible cores, a unit (2) for injection moulding, a unit (3) for melting and for recovering the fusible cores and a unit (4) for washing the moulded parts. The first two units are served by a mobile transfer robot (5) equipped with a rotatable arm having a ripper adapted to catch a fusible core and a gripper adapted to catch a moulded part. The two latter units are served by a stationary robot for melting (8) which interacts with the transfer robot (5). By programming the various functions performed by the robots, it is possible to carry out in parallel the moulding cycles of fusible cores and of injection moulding of the desired parts with a minimum of non-productive time and hence to obtain an automatic production with a high yield.

Abstract: A method of forming a fastener member having a base and a plurality of headed stems arranged in columns and rows and projecting from the base. The fastener member is formed by injection molding a molten material into a base mold, sacrificial stem mold and head mold, wherein the material is solidified. After the base mold and head mold are removed, the stem mold may be destructively removed to release the fastener member.

Abstract: A core for producing a molded resin product having a bent hollow portion, including two-forked and multi-forked products used as parts for automobiles, and a process for producing the aforesaid resin product having a bent hollow portion by using said core.

Abstract: A plunger (10) for supporting a wall (46) of e.g. a refrigerator door against deformation from an expanding, and hardening foamed plastic (52) on the other side of the wall. An evacuated bag-formed part (18) filled with a particulate material (20), has a surface (42) showing an impression of the form of the wall (46). The plunger (10) is reshapable, so that it can serve as a plunger for walls (46) of different forms.

Abstract: Disclosed herein is a die member for forming a lost foam pattern for casting a cylinder block having a cylindrical bore with an axis and a helical transfer passage including a first portion permitting die member separation in a direction along the axis of the cylindrical bore and a second undercut portion preventing one-piece die member separation in the direction along the axis of the cylindrical bore, which die member comprises a projection forming a first cavity corresponding to a first part of the first portion of the transfer passage, and a core carried by the die member and movable relative to the die member between an extended position forming a second cavity corresponding to a second part of the first portion of the transfer passage and the undercut portion of the transfer passage, and a retracted position affording separation of said core through the second part of the first portion of the transfer passage and in common with separation of said projection from the first portion of the transfer passage

Abstract: A method for the manufacture of a mold out of mold material from a previous blank by machining each blank into a desired shape by means of a machine tool controlled by a computer utilizing a dimensioning data set. Each blank is manufactured by feeding an organic polymer material whose melting point is preferably lower than 150.degree. C. in liquid form into a box-shaped container which is open at the top and which corresponds to the dimensions of the desired mold. Waste polymer material from the blank upon machining is recovered and heated to a temperature higher than its melting point, whereupon it is fed onto an existing mold no longer needed, so as to provide a new blank for a new mold.

Abstract: Method and apparatus is provided for reinforcing a structural member of a vehicle body by the use of adhesively bonded together glass macrospheres of 3 to 9 mm. in diameter. The adhesive is not more than about 40% by weight of the mixture so that voids remain between the adjacent macrospheres to permit airflow through the reinforcement and the reinforced structural member upon curing adhesive. The adhesive may be curable at ambient temperature or may be a high temperature curable adhesive which is cured in a vehicle body paint curing over to bond the macropsheres to one another and to the structural member. The adhesion of the macrospheres to the structural member may be facilitated by an epoxy coated flexible sheet material lining the walls of the structural member. The adhesive coated macrospheres may be closely packed into the structural member by pouring or blowing.

Abstract: An insulated welded wire structural building panel and a method for making such panels are disclosed. The panel has a plurality of parallel trusses joined together with cross wires. Each truss is triangular in cross section. A layer of polyurethane foam is provided in the panel spaced from both the front side and the back side of the panel. On one surface of the foam is a layer of solidified viscous material, such as asphalt or a thermoplastic. The cross wires on opposite sides of the panel are offset from each other along the axes of the truss runner wires to which they are welded.

Abstract: A one-piece, hollow, moulded head for a golf-club of the "wood" or "driver" type is made by injecting a thermoplastics material around a fusible core having a melting-point below the injection temperature, allowing the injected material to set and melting out the core.One or more holes are provided, the holes extending completely through the core, so that the injected material fills each hole and sets therein to provide corresponding internal "struts" in the moulding.The injected material may be, e.g., a polyamide, a polycarbonate, a poly(phenylene oxide), an acetal resin or an ABS resin. The material may be reinforced with up to 50% by weight of glass and/or carbon fibres.The moulded head may optionally be filled with a polyurethane foam.The finished moulding may have the conventional face-pieces and/or sole-plates attached thereto.

Abstract: Method and apparatus is provided for reinforcing a structural member of a vehicle body by the use of adhesively bonded together glass macrospheres of 3 to 9 mm. in diameter. The adhesive is not more than about 40% by weight of the mixture so that voids remain between the adjacent macrospheres to permit airflow through the reinforcement and the reinforced structural member upon curing adhesive. The adhesive may be curable at ambient temperature or may be a high temperature curable adhesive which is cured in a vehicle body paint curing oven to bond the macrospheres to one another and to the structural member. The adhesion of the macrospheres to the structural member may be facilitated by an epoxy coated flexible sheet material lining the walls of the structural member. The adhesive coated macrospheres may be closely packed into the structural member by pouring or blowing.

Abstract: In order to prepare thermoplastic polyurethane elastomers(a) organic diisocyanate,(b) polyhydroxyl compounds with molecular weights of 500 to 8,000, and(c) chain extenders with molecular weights of 60 to 400 in the presence of(d) catalysts, and optionally(e) auxiliaries, and/or(f) additivesare reacted in two reaction stages at temperatures from 60.degree. C. to 250.degree. C. In the first reaction stage the components are continuously mixed, the reaction mixture is applied to a carrier, preferably a conveyor band of thermoplastic material, and is allowed to react at the reaction temperature until solidified. Subsequently, the solidified reaction mixture is melted in an extruder and the reaction is completed in the second reaction stage.

Abstract: The invention relates to a factory prefabrication method for hollow panels for the on-site erection of insulated constructions.This method employs a three-dimensional framework 1 composed of thrust bars arranged in two parallel planes and of link bars linking the former. The method consists in placing said framework in a mold 13 containing a pulverulent material 16 wherein the framework is embedded by part of its thickness, in molding an insulating synthetic material 4 in the empty part of the mold so as to embed the visible parts of the framework 1, in placing above the mold a form sheet 2 so that the insulating material shall make contact with it and adhere to it during hardening, and after this hardening, in extracting the pulverulent material and in ejecting the obtained panel. The panel so manufactured can be provided after ejection with a second form sheet opposite the first.

Abstract: A method is provided for making shaped self-supporting carbon-fiber structure by initially forming a fluid mixture of curable binder and carbon-fiber. The mixture is poured into a mold, and a vacuum is applied to the mold to effect the separation of excess binder. Cure is effected of the residual binder to produce a removable self-supporting shaped carbon-fiber structure.

Abstract: A curved mandrel, method of making same, and method of curing an uncured polymeric hose employing such curved mandrel are provided and the curved mandrel comprises a plurality of members disposed in end-to-end relation to define the configuration of the mandrel including a predetermined curvature therein, interlocking portions for interlocking the members in only one position to define the configuration and curvature, and a readily attachable and detachable device for holding the members axially against each other after interlocking wherein the members with the interlocking portions and holding device are adapted to provide a substantially straight mandrel for installation of an uncured straight hose therearound, define the configuration and curvature in the mandrel and uncured hose, and provide looseness and axial spacing between members to enable easy withdrawal of the cured curved hose from around the members.

Abstract: A one-piece, homogeneous electrical connector insulator is disclosed having an integral contact retention cone in each contact passage thereof. The insulator is made by the use of a mold having two core pins for each contact passage, and a suitably formed bushing positioned between the core pins which is removed by etching after the core pins are withdrawn from the molded insulator.

Abstract: The present invention relates to a method for manufacturing a refractory erial having numerous through pores in a certain direction. The refractory material is manufactured by covering a woven fabric composed of combustible weft and/or warp threads with a slurry of a refractory material, and then drying and baking the coated fabric to burn out the combustible yarns so that the desired through pores may be obtained in directions corresponding to the direction of the burned out weft and warp threads.

Abstract: A method of making a panel for installation in the high velocity air flow region of an engine nacelle and other applications requiring sound absorbing material and increased air frame strength. The panel utilizes a single layer of either a metallic or nonmetallic cellular core with a solid or perforated septum disposed internally therein. The septum may have a planar or nonplanar configuration within the individual cells of the core thereby providing means for reducing the noise level of various sound frequencies created by a jet engine or any other sound producing devices for that matter. The planar or nonplanar septum provides structural stabilization and/or vibration dampening to a bonded sandwich assembly. The panel may also be used in strengthening air frame construction and other applications besides sound attenuating panels.

Abstract: A three-dimensional network porous metallic structure is formed by filling the internal cavity of a mold, which has been prepared by making use of a three-dimensional network resin pattern, through driving the molten metal into the cavity by a pressure or through sucking the molten metal into the cavity by reducing the pressure in the cavity. The porous metallic structure thus obtained is characterized by a large specific surface area, as well as a reduced pressure drop of fluid passing through this structure, and, therefore, is fit for various uses such as the material of fins of heat exchangers, various filters and so forth.

Abstract: A method of building a closed tube-tire includes constructing a green tire carcass (13) on a disintegratable core (17) and curing the tire carcass (13) in a curing mold (10) having two halves (11,12) which are movable between opened and closed positions. The green tire carcass (13) is intentionally constructed undersized so that a space (18) exists between the green tire carcass (13) and the curing mold (10) to prevent the core (17) from being cracked or crushed when the halves are closed around the tire carcass (13).

Abstract: This invention relates to a moldable foamed polymer composition that can be molded at relatively low ambient temperatures and pressures. The moldable composition comprises a wax and particles of a foamed polymer, the wax being present in an amount capable of bonding the particles together in a coherent body. A method for forming articles from said composition along with processes for using said molded articles are also disclosed.

Abstract: The crushability of a ceramic article suitable for use in the casting and directional solidification of advanced superalloy materials is enhanced by utilizing a two-phase mixture of material and inducing microcracks in the material. The crushability is further enhanced by forming the article to include a predetermined porosity content.

Abstract: A compactible mold pack useful for forming articles of complex inner and outer contour and substantial uniform density directly from metal powder is disclosed. The mold pack includes first and second porous, compactible mold sections defining therebetween a cavity in the outer contour of the article to be made, a porous, compactible core suspended in the cavity to define the inner contour and metal powder disposed in the cavity between the mold sections and core, the mold sections and core having an initial porosity substantially equal to that of the metal powder to be consolidated. The mold pack may be compacted to size by conventional forging and pressing techniques to consolidate the metal powder therein into the desired article.

Abstract: A new pyrotechnic munition having an expendable and disintegrable mandrel d a process of manufacture thereof.

Abstract: An apparatus is disclosed for the continuous manufacture of fiber reinforced plaster sheets which apparatus includes a conveyer for supporting a plurality of sheet casting moulds, a casting station for casting slurry into said moulds and a fiber station at which means are provided for depositing fiber for reinforcement across the surface of the casting slurry. The apparatus also includes a pair of rollers having radial extensions to force the fibers to or adjacent the lower surface of the cast slurry. A second fiber depositing means is also provided for depositing a second batch of reinforcing fibers across the surface of the slurry and a second pair of rollers having an open mesh surface are provided for forcing the second batch of fibers into the slurry to a level at or adjacent the upper surface thereof. The fibers used may be sisal or fiberglas as individual randomly oriented lengths, continuous meandering strands or a random mat deposited over the surface of the slurry.