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: For the production of a steering wheel with a seamless casing, surrounding the steering wheel rim, the steering wheel spokes and the central region for an airbag covering with tear-open lines, of a plastic moulded part produced in one piece by casting or injection moulding, with a closed surface and a possibly foamed base body, a method is proposed which is characterized in that a core of a low-melting material is fastened to the central base part of the steering wheel skeleton structure, that thereafter the steering wheel skeleton structure and the core are placed into a mould for the formation of the plastic moulded part, that the plastic moulded part is produced and that after the setting of the plastic moulded part, the core is melted by an increase in temperature and the material is removed in liquid form from the plastic moulded part.

Abstract: A method for producing high performance components by the consolidation of powdered materials under conditions of hot isostatic pressure. The method uses the inclusion of reactive materials mixed into pressure-transmitting mold materials and into the powder to be consolidated to contribute to in-situ materials modification including purification, chemical transformation, and reinforcement. The method also uses encapsulation of the mold in a sealed container to retain the mold material in position, and to exclude air and contaminants.

Abstract: An electronic part having a complicated internal configuration is integrally molded without dividing the configuration into a plurality of sections, thereby reducing the cost and improving the quality of the electronic part.

Abstract: A flexible and resilient positive pattern is made for a desired high temperature metal or ceramic part such as a gas turbine impeller having a complex geometry with walls defining undercut spaces, and the pattern with flexible walls is dipped into a ceramic molding media capable of drying and hardening. The pattern is removed from the media to form a ceramic layer on the flexible pattern, and the layer is coated with sand and air dried to form a ceramic layer. The dipping, sanding and drying operations are repeated several times to form a multiple layer ceramic shell. The flexible wall pattern is removed from the shell, by partially collapsing with suction if necessary, to form a first ceramic shell mold with a negative cavity defining the part and to provide for reusing the pattern. A second ceramic shell mold is formed on the first shell mold to define the back of the part and a pour passage, and the combined shell molds are fired in a kiln.

Abstract: An electronic part, which has a complicated internal configuration and has a movable part rotatably and movably accommodated therein, is integrally molded without dividing the configuration into a plurality of sections to carry out a number of molding operations for separate sections of the electronic part, thereby reducing the cost and enhancing the quality of the electronic part.

Abstract: An implant having an integrally-textured, hemocompatible blood-contacting surface and a method for producing the same is provided. The implantable device can include a device body having a textured surface and a predefined complex shape, such as a bladder or a generally U-shaped conduit. The device body can be composed of a first device material, and the textured surface can be formed of a second device material on the obverse side of the device. The textured surface can have multiple, blood-compatible structures integrally formed thereon. The structures can be fibrils that are suitable for a generally uniform biological layer to be established thereupon.

Abstract: The invention relates to a material of a three-dimensional framework of supporting, trabecular structures encompassing cavities which are connected with one another and which can be predeterminedly adjusted. The material is obtainable by forming the framework around the shaped bodies serving as space retainers for the cavities and subsequently removing the shaped bodies. The material according to the invention can be used for example as a implant or as a filter.

Abstract: A golf club shaft manufacturing process for making a lightweight golf club shaft that is not uniformly tapered along its length by using standard table-rolling tools and equipment. The process consists generally of creating one or more hollow sleeves and securing them around the exterior of a mandrel, the sleeves having a length and an exterior shape equal to the desired dimensions of the non-tapered portions of the shaft. Graphite flags are then rolled around the mandrel and sleeve, shrink tape is applied and the entire assembly is placed in a curing oven to cure the graphite shaft. The curing temperature is less than the melting point of either the mandrel or sleeve. Once the shaft has been cured, the shrink tape is removed and the mandrel is extracted. The remaining shaft and sleeve assembly is heated to a temperature greater than the melting point of the sleeve material so that the sleeve is liquefied and can be poured out of the shaft. The cured shaft can then be cut, sanded and finished as desired.

Abstract: The present invention is a process for making a nanochannel glass (NCG) rica, having the steps of: coating a face of an etched NCG with a replica material (with or without an intervening buffer layer), where the etched NCG face has a plurality of channels arranged in a desired pattern, to form a replica coating on the NCG conforming to the pattern; and removing the replica coating from the etched NCG. The present invention is also the replica made by this process.

Abstract: A method for preparing mimics of a wide variety of drugs and other biologlly active molecules using molecular imprinting techniques, and the mimics produced thereby, is disclosed. Specifically, the mimic is designed by: (i) polymerization of functional monomers around a known drug or biologically active molecule (the template) that exhibits a desired activity; (ii) removal of the template molecule; and then (iii) polymerization of a second class of monomers in the void left by the template, to provide a new organic molecule which exhibits one or more desired properties which are similar to that of the template.

Abstract: A method of fabricating complex hollow composite structures from laminates of fiber reinforced synthetic resins. The structures are fully monocoque tubes with no seams. The tubes are manufactured by wrapping a hollow semi-rigid inner mandrel made of thermoplastic material such as polystyrene or ABS (acrylonitrile-butadiene-styrene co-polymer) with layers of composite sheets. The sheets are made from high-strength fibers impregnated with thermosetting or thermoplastic resins.The laminated mandrel is placed in a mold, heated and inflated to a predetermined pressure. The pressure can range from 20-200 psig and even higher, while the curing temperature can range from 200.degree.-600.degree. F. The pressure generated by the expanding core produces a highly consolidated composite structure that has fewer voids, a more uniform thickness, and an increased fiber content compared to hollow composites made by other fabrication methods.

Abstract: A method for consolidating powdered material to near net shape and full density is provided. The method includes the steps of: mixing a particulate material with an organic or inorganic binder to form a mold material; shaping the mold material into a mold having a shape and including an external surface and an interior cavity and being of sufficient solidity to maintain its shape yet being compressible under pressure; filling the interior cavity with a powdered material to be consolidated; heating the mold with the powdered material therein to form a heated filled mold; applying pressure to the external surface of the mold sufficient to compress the mold material and transfer a pressurizing force to the powdered material within the mold cavity so as to consolidate the powder and form an article; and removing the article from the mold. In an alternative method, the mold material is made of a particulate material which is held in the shape of the mold by a vacuum.

Abstract: Plural non-pneumatic (NPTs) are unitarily fitted, side-by-side, on a wheel rim, forming a multiple NPT (MNPT) to carry a load by sharing the load between the side-by-side NPTs. By "unitarily" is meant that the NPTs are fitted to the rim as a whole, without cutting or sectioning. With this construction, a MNPT is provided; with characteristics which are surprisingly better than those attributable to a single NPT having the same or a different outer hoop diameter but the same mass of resin as the plural NPTs. The NPTs may be formed as rings, then by heat-distending them, unitarily post-fitted to the surface of an adhesively prepped wheel rim, for operation at relatively low torque; alternatively, and more preferably the NPTs are cast or otherwise thermoformed, as for example by injection molding, onto the wheel rim and self-adhesively autogenously secured, so as to provide the plural NPTs integrally bonded to the wheel rim.

Abstract: In a process for manufacturing a bow rake, an outer plastic encasement is molded over a structural skeleton to form a cross-head including a handle-receiving socket and a plurality of spaced-apart tines. An elongated claw is pressed into an end of each tine, and an end of a handle is securing within the handle-receiving socket. In manufacturing the cross-head, one or more voids in the structural skeleton are filled with a selected flowable filler material which provides a structural backstop to maintain the shape integrity of the hollow skeleton during the molding step. Some or all of the filler material is removed from the skeleton subsequent to the molding step. Prior to pressing the claws into the tines, the claws are heated and then secured on a ram. The cross head is placed in a stationary jig in alignment with the ram, and the heated claw is then pressed into the selected tine. A similar process is utilized to connect the handle to the cross-head.

Abstract: A method is provided for installing a refractory lining in a metallurgical vessel having a main opening which is much smaller than the diameter of the vessel. The method is especially useful in a vessel having a circular or otherwise curved cross-section. A form or mold is assembled inside the vessel, leaving a space between the form and the outer shell of the vessel. The form is supported on both sides, to maintain the distance between the form and the outer shell, and to prevent collapse or implosion of the form. Then, a pumpable casting composition having a smooth and easy flow is injected between the form and the shell, and allowed to harden. The use of the pumpable composition significantly shortens the time required to form the liner.

Abstract: A process and apparatus is provided for molding flowable materials. The mold may be provided with deformable or collapsible mold surfaces and a forming member which is positioned in the mold when producing a shell molded article is also deformable or collapsible. After the molded article is formed the forming member and/or the mold surfaces are deformed or collapsed to facilitate removal of the article from the mold and to avoid "backlocking" of the article in the mold.

Abstract: An improved manufacturing process is provided for surface protective striking tools such as hammers and mallets. An elongate hollow core is fitted with impact heads at opposite ends thereof and filled with a flowable filler material such as small steel pellets prior to placement of the core into a mold cavity for injection mold formation of an outer encasement. During the molding step, the filler material provides a substantially rigid structural backstop which enables a core of lightweight construction to withstand typical injection molding parameters. The molded outer encasement ensheathes a skirt portion of the impact heads and any exposed portion of the core member to bind the impact heads to the core member. The molded outer encasement does not extend over an impact face of each impact head. A handle may also be molded with the outer encasement. A striking tool thus formed is removed from the mold, and some or all of the filler material is drained from the core through an open port.

Abstract: A method for making an offset corrugated core sandwich construction is diosed. Mandrels of preestablished form and size are arranged into a pattern in a confined area. After covering the mandrels with a release film, strips of pliable, uncured composite material are arranged in a "peak-to-valley" pattern with adjacent strips being out of phase by 180 degrees. Selected mandrels are replaced by a granular mixture and top and bottom face sheets are fitted to the arrangement. After curing, all mandrels are removed from the construction.

Abstract: The method includes mixing (100) degradable consumable cores (11) with a liquid coating composition (20) including an aqueous solvent (21), a hydrosoluble resin (22) and an anti-agglomerant additive (23), drying (200) the coated cores so as to obtain free balls (12) with a substrate film (2), mixing (300) these balls (12) first of all with a liquid covering substance (30) including a synthetic base product (31) and optionally an auxiliary product (32), then with an anti-agglutinant adjuvant (33), drying (400) the covered balls so as to obtain free ball structures (13) with a covering layer (3), and stoving (500) these ball structures so as to harden their covering layer and degrade the cores and thereby obtain hollow spherules (10). Application in the manufacture of intermediate products for producing in particular energy absorbers.

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 process for producing a cylindrical reinforcing fibrous molding by sealing openings at opposite ends of a porous cylindrical disintegratable mold, immersing the mold into an aqueous solution of a molding material containing reinforcing fibers and an inorganic binder, and depositing the molding material onto the outer peripheral surface of the mold by applying suction within the mold to form a molding blank; pressing the molding blank against the mold to adjust the shape of the molding blank; disintegrating the mold to remove it from the blank; and heating the molding blank to partially bond the reinforcing fibers with the inorganic binder.

Abstract: Sand cores are removed from metal or plastic coatings by exposing the cores to a humid atmosphere for a sufficient time to weaken the binder of the sand cores. The sand is then shaken from the casting. Metal or plastic castings with hollow passages are produced by forming a casting around the sand core bound with a suitable binder followed by exposing the casting and sand core to a humid atmosphere and then shaking the sand from the casting.

Abstract: In the manufacture of a wax pattern for use in the lost wax casting of a bladed rotor of the radial flow type, the bladed region of a master pattern is enclosed by a curable epoxy resin/aluminium powder composition. Sufficient of the cured resin composition is then machined away so that a plurality of resin composition segments are defined, one segment being interposed between adjacent blades on the master pattern. The segments are then removed from the master pattern and placed in an appropriately configured die member so as to define a complete die for the production of a wax pattern in the form of the master pattern.

Abstract: A process and device for producing a rubber tube having a smooth outside surface in which a molten synthetic resin is heated from the inner circumferential side immediately before it flows from a die along the periphery of a rubber material layer and the rubber mentioned is cooled within the die.

Abstract: An elastomer-coated fabric for use as a confinement. The confinement is formed by conforming a fabric to a mold having the shape of the desired confinement, and subsequently applying a layer of elastomer to the fabric. A curing operation then cures the elastomer such that the elastomer-coated fabric retains the shape of the mold. Advantageously, the curing operation also relaxes and heat sets the fabric in order to permit a controlled amount of further stretch, even if the fabric was stretched a maximum amount when it was conformed to the mold.

Abstract: A process for pressure molding an article around a hardened salt mold core made from a mixture of relatively low melting temperature salt and sand wherein the core is removed from the finished article by immersion of the article containing the core into a molten bath mixture of the core material thereby to melt the core out of the article, recover the core material, and thus replenish the bath for use in making additional cores. The bath is originally constituted by melting a suitable quantity of a dry premix of the salt and sand.

Abstract: A process is disclosed for making a casting nozzle wherein gas can be blown out through the outlet of the nozzle to prevent the sticking of nonmetallic impurities to the nozzle during use. Reticulate organic filaments in the form, e.g., of a net are applied around a preformed inner cylindrical refractory body having a pouring hole therein. An outer cylinder body is then formed around the inner cylinder body including the organic filaments. The entire body is then fired, whereby the organic filaments carbonize and evaporate, leaving a network of gas-permeable reticulate holes in the body. An outlet is drilled or cut in the fired body through the gas-permeable holes to the pouring holes. Accordingly, when the nozzle is in use, a blowing gas can be provided through the reticulate holes to the nozzle outlet to prevent the sticking of nonmetallic impurities.

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: A method of destroying a brittle body by molding around an elastic tube or an elastic tube in which is inserted a plastic wire or a heat-fusible member for defining a charging hole where the member or tube is partly exposed at the surface of the brittle body, and, after pulling out the elastic tube or fusing the heat-fusible member, an expandable splitting agent capable of expanding by hydration is charged into the charging hole and subjected to hydration-expansion to destroy the brittle body. In another form, a water-impermeable film enclosing an expandable splitting agent capable of expanding by hydration therein is previously buried in a brittle body in a relation partly exposed at the surface of the brittle body, and, after aperturing the exposed end of the water-impermeable film, the expandable splitting agent is subjected to hydration-expansion to destroy the brittle body.

Abstract: A mold forming method in which a pattern is made of an organic material such as foamed polystyrene and at least a portion of the outer or inner surface of the mold pattern is covered by a thin coating, and surrounded with a mold material. The pattern is then dissolved by a solvent, leaving the coating undissolved. The coating is finally removed by a solvent contained in a slip which is poured into the cavity provided with the coating.

Abstract: A method for producing nonspherical particles including those of prolate spheroidal, oblate spheroidal, and ellipsoidal shape is described. A microparticulate latex can be produced wherein the microparticles in the latex are substantially identical in all dimensions. The overall shape, volume, and aspect ratio or aspect ratios of the particles can be systematically controlled. Non-spherical particles ranging in sizes from about 0.01 microns to about 100 microns can be produced from a variety of polymeric materials. Such particles can be used as model particles for a variety of scientific studies, calibration standards for electron microscopes, and in a variety of optical, thermal, electrical, and biomedical applications.

Abstract: Ceramic porous bodies, including ceramic foam filters and smooth-faced ceramic objects, e.g., ceramic foam bricks, ceramic foam melting crucibles, and ceramic foam cores, made in accordance with the present invention are suitable for use with molten metal in general and molten superalloys in particular. The invention also provides a tundish for use with ceramic foam filters to filter metal en route from a metal furnace to a casting mold, and a melting device for use in casting metal which employs a ceramic foam filter as a bottom pour valve for a melting crucible such that the ceramic foam filter valve regulates the flow of molten metal therethrough in order to permit an entire ingot of metal to melt in the melting crucible before any metal begins to pour from the melting device into a casting mold.

Abstract: An ultra-light structure is produced by continuously molding a greensand core, forming a material in the mold pattern in the core which solidifies to form a solidified framework, and removing the greensand core.

Abstract: A method of manufacturing a ceramic body having continuous three-dimension through-out holes which can be preferably employed as a filter for filtration of non-metallic inclusions in a molten metal and as a porous plug for introducing a gaseous medium for floating up the non-metallic inclusions. An organic body having a three-dimensional construction is placed in a casting mold, a slip of a ceramic material is poured into the mold, and after drying, the molded body is baked to effect decomposition of the organic porous body. Thus the ceramic body is provided with through-out holes communicating with to each other three-dimensionally together with a high mechanical strength.

Abstract: In production of a golf club head by heat pressing of a compound in a splittable mould, the compound of a fixed weight is injected into the mould cavity through an injection tube which is clamped by the mould and removed after appreciable hardening of the compound. Provision of an asylum for extra bulk of compound by the injection tube remarkably reduces production of undesirable dregs or flash at heat pressing. The injection tube also serves to define the correct positioning of a core used in the product.

Abstract: First and second clamshell-shaped foam members are mated, the first and second foam members meeting along exteriorly exposed joint margins defined by mateable surfaces extending along opposite sides of each of the members. At least one other foam member is nested totally within the mated assembly of the first and second members and nested without joint margins exposed to the exterior of the mated assembly. The surfaces enclosed within the mated assembly pilot the first, second and other members into mating relationship. The first and other members are adhesively bonded together and the second member is adhesively bonded to the assembly of the first and other member.

Abstract: A diaphragm for loudspeakers and the like comprises a diaphragm base component formed of ceramics of a three-dimensional network structure so as to be light in weight, high in bending stiffness, easy to make and high in sound velocity. The diaphragm base component is sealed by a sealing material so as to be made air-permeable. This diaphragm is made by impregnating combustible foamed plastics material with a ceramic slurry, baking the ceramic impregnated foamed plastics to burn off the foamed plastics material, and the diaphragm base component sealing with the sealing material.

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: This invention relates to a process for the production of an implant of metal or plastics material having an open-celled structure as a bone substitute. The process uses a connectively open-celled pattern material having a spatial grid or lattice network structure, the cells or pores of the material being defined or formed by very fine thin interconnected threads or cords. The thin threads are coated by a wax-water emulsion which is combustible and vaporizable. A stabilization of the coating may be performed by spraying-on of a hardening and vaporizable synthetic material lacquer, which is deposited on the wax coating. A core material is introduced into the residual hollow spaces of the pattern, which is consolidated by heat, the pattern material being burnt and vaporized while doing so, together with the adhering material and the lacquer without leaving behind any residues, so that the cavities formed in the core may be filled with the implant material and the core material is finally removed.

Abstract: An ultra-light structure is produced by continuously molding a green sand core, forming a material in the mold pattern in the core which solidifies to form a solidified framework, removing the green sand core and wrapping the resultant solidified framework structure in a material.

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: A tooth crown or the like fixed, custom fitted dental appliance made of a fired ceramic which undergoes substantially no shrinkage when fired, the appliance being made by forming a compact of the raw prefired ceramic with an undersurface shaped for a precise fit onto the prepared tooth on which the appliance is to be used, and thereafter firing the compact to a dense hard monolithic structure.

Abstract: A method and apparatus for casting of fragile complex shapes by the formation of a two layer wax mold about a pattern of the shape to be cast. Thereafter, the pattern is removed from the mold and the outer layer of wax dissolved. The slip is then poured into the mold and allowed to solidify before the inner layer of the mold is completely removed from the cast article.

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 for insulating a water heater with foamed insulation comprises inflating a tube in the cavity between the shell and the tank to define a boundary for the cavity into which the insulating material is injected. The device is deflated after the foamed insulation has set in the cavity. Apparatus for carrying out such method is provided.

Abstract: Polymeric sheets having on one or both sides a fabric texture and, optionally, a network of elongated channels in the interior of the structural framework of the sheets are disclosed. The sheets are useful as burn coverings where they serve as synthetic, temporary replacements for damaged or missing skin. The sheets have physiologic properties similar to human skin, excellent drapability characteristics, recessed portions which provide a reservoir for wound debris and, in certain embodiments, a dermal surface which permits wound adherence by fibroblastic ingrowth.In one embodiment, laminated sheets in which only one side has a fabric texture are prepared by (1) applying one or more layers of polymer to a support surface, (2) partially embedding a sheet having a fabric texture in the layer of polymer, (3) curing or hardening the polymer to form a composite of the sheet and polymer, and (4) separating the composite from the forming surface.

Abstract: A destructible core is formed from a frangible plastic shell filled with inert ballast. The core is used for forming complex cavities in the production of cast resin parts.