A vacuum molding process uses a flexible molding skin having an imprint face arranged inside an airtight compartment. Before the vacuum is made, a pasty plastic material is incorporated in the compartment facing the imprint The vacuum is then made in the compartment to press the flexible molding skin onto the plastic material with formation of a molded surface with sculptures and asperities giving a decorative or functional granular appearance. The molding skin is made of a flexible anti-adhesive organic material, notably silicone, for ease of removal from the mold after the plastic material has hardened Shaping of the panel is performed after the vacuum bag has been positioned on a shaping part. The process is used for manufacturing artificial climbing wall panels.

Vacuum molding process for making a panel made of plastic material

A reusable die for the manufacture of molded seat cushions that includes a first device for forming a positive profile of a contoured surface, such as a seating support surface, from data obtained for defining the positive surface profile; and a second device for forming a negative profile of the contoured surface, whereby the first surface is adapted to be maintained in contact with the second surface. The first device includes a plurality of rods adapted to define the positive profile. The second device also includes a plurality of rods and a deformable member, such as a wire mesh, that coact with the rods of the first device to form the negative profile. The rods of both the first device and the second device are adapted to be locked in place. A sealing surface is vacuum formed over the negative profile, which then forms a wall of a foam mold. Liquid foam material is then injected in the mold and permitted to cure thereby forming a contoured seat cushion. Also disclosed is a method to manufacture a contoured seat cushion.

Reusable die shape for the manufacture of molded cushions

A mandrel for composite fabrication includes an open cell foam carrier and at least one vacuum bag enclosing the open cell foam carrier.

Bagging process and mandrel for fabrication of elongated composite structure

Methods of manufacturing a modular, monolithic, integrated, multi-layered, mold building structure including the steps of constructing a dismantleable mold having an outer rigid matrix and an inner inflatable plug, wherein the inside dimensions of the matrix correspond to the outside dimensions of the structure and the outside dimensions of the plug correspond to the inside dimensions of the structure, placing high strength fibers between the plug and the matrix, injecting hardenable material between the matrix and the plug, curing the hardenable material into a hard shell, removing the matrix, deflating the plug, and installing walls, doors or windows. The structures may be joined together on-site in various combinations and configurations to create different types and styles of buildings.

Method of molding monolithic building structure

A method and apparatus for forming a member, such as a column. The invention comprises inner and outer molds that are spaced apart forming a cavity for receiving a viscous material for making the member. A core is inserted within the inner area of inner mold when the viscous material is initially disposed within the mold. Once the material attains a gelled state, an extraction member is inserted within the inner area. A vacuum is applied to the inner area that causes the flexible inner mold to separate from the material and conform to the extraction member allowing for removal.

Mold and molding process

Pneumatic means comprising a hollow mandrel or hollow tube having secured around its outer surface along the length thereof according to one embodiment, a flexible open-cell polyurethane foam sleeve and an outer skin formed of a flexible non-permeable plastic such as a vinyl plastic skin adhesively secured to the outer surface of the flexible open-cell foam sleeve, and air passages for communication between the interior of the mandrel and the open-cell foam sleeve, the resulting assembly being positioned in a mold for production of cored structural panels. In operation the tool assembly is placed under pressure and expanded to force the plastic skin of the assembly outwardly during pouring and setting of the construction material, e.g., a cement or cement-polymer composition in a mold, and after setting thereof the tool assembly is subjected to reduced pressure or a vacuum to withdraw the plastic skin from the set composition, e.g., in the form of a molded panel, to facilitate removal of the tool from the molded panel, thereby forming a cored construction material or panel. Also included as a feature, pneumatic means in the form of a bellows arrangement comprising an external flexible, e.g., rubber, corrugated member, and in the interior of such corrugated member a permeable open-cell, e.g., polyurethane, foam, and tensioning means, said bellows being inflatable for applying pressure to force a contact, e.g., honeycomb, member mounted on the bellows, against an outer surface of a casting composition in a mold, to form an outer surface for a structural molded panel, and which bellows can be deflated to facilitate removal of the pneumatic tool and associated members from the mold following setting of the panel construction. Also included, means providing a combination or arrangement of a plurality of both said mandrel and bellows assemblies for provision of a cored molded structural panel containing outer surfaces of a predetermined, e.g., smooth or textured, configuration.

Carrol C Sachs

Papers

Pneumatic means for production of molded structures

Resin impregnating machine for fabric or like material

Linear extruding apparatus

Structural panel forming machine

Structural panel forming machine and method