Process for shaping articles from electrosetting compositions

Claim 2

A process for shaping articles, comprising: providing a quantity of fluid electrosetting composition; positioning a first portion of said electrosetting composition between at least two electrically conductive surfaces, said electrosetting composition comprising a phase changing vehicle which is both a dielectric and a polymer and an aggregate comprising particles which will polarize in an electric field; electrically charging said conductive surfaces such that said first portion of said electrosetting composition solidifies electrically in the manner of an electrorheological fluid; maintaining said charging such that the cure of said first portion of said electrosetting composition is accelerated; wherein the part of said quantity of said electrosetting composition which was not placed between said electrically conductive surfaces remains fluid; and separating said fluid portion from the solidified first portion of said electrosetting composition.

Claim 3

A process for making articles, comprising: positioning an electrosetting composition between first and second surfaces, each said surface having substantially opposite conductive and nonconductive portions, said electrosetting composition comprising a phase changing vehicle which is both a dielectric and a polymer and an aggregate comprising particles which will polarize in an electric field, said electrosetting composition further comprising a composition which is an electrorheological fluid, is castable or moldable and is curable in the presence of an electric field wherein the field provides electrical acceleration of the cure of said composition, wherein said cure is defined as the electrically irreversible phase change of said composition from fluid phase to solid phase, wherein said electrically irreversible phase change is defined as a solidification of said composition such that said solidification is not reversible by means of removing said composition from being positioned within an electric field; electrically charging said conductive portions of said first and second surfaces thereby electrically energizing only the portion of said electrosetting composition between said conductive portions of said first and second surfaces while the remaining portion of said electrosetting composition is unenergized; maintaining said charging until said energized portion of said composition adjacent the conductive portions of said first and second surfaces has cured; and separating excess uncured composition substantially corresponding to non-conductive portions of said first and second surfaces from said cured portion.

Claim 4

A process for making articles, comprising: positioning an electrosetting composition between first and second surfaces, each said surface having substantially opposite conductive and nonconductive portions, said electrosetting composition comprising a phase changing vehicle which is both a dielectric and a polymer and an aggregate comprising particles which will polarize in an electric field, said electrosetting composition further comprising a composition which is an electrorheological fluid, is castable or moldable and is curable in the presence of an electric field wherein the field provides electrical acceleration of the cure of said composition, wherein said cure is defined as the electrically irreversible phase change of said composition from fluid phase to solid phase, wherein said electrically irreversible phase change is defined as a solidification of said composition such that said solidification is not reversible by means of removing said composition from being positioned within an electric field; electrically charging said conductive portions of said first and second surfaces thereby electrically energizing only the portion of said electrosetting composition between said conductive portions of said first and second surfaces while the remaining portion of said electrosetting composition is unenergized; maintaining said charging until said energized portion of said composition adjacent the conductive portions of said first and second surfaces has cured; and separating excess uncured composition substantially corresponding to non-conductive portions of said first and second surfaces from said cured portion.

Claim 5

A process as described in claim 2 wherein the phase changing vehicle comprises polyurethane.

Claim 6

A process as described in claim 2 wherein the phase changing vehicle comprises epoxy.

Claim 7

A process as described in claim 2 wherein the particles comprise glass microspheres.

Claim 8

A process as described in claim 2 wherein the particles comprise corn starch.

Claim 9

A process as described in claim 2 wherein the phase changing vehicle comprises silicone rubber.

Claim 10

A process as described in claim 2 wherein the particles comprise aluminum.

Claim 11

A process as described in claim 2 wherein the particles comprise graphite.

Claim 12

A process as described in claim 2 wherein the phase changing vehicle comprises rubber cement.

Claim 13

A process as described in claim 2 wherein the particles comprise cellulose.

Claim 14

A process comprising: positioning an electrosetting composition between two surfaces each said surface having substantially opposite conductive and nonconductive portions, said electrosetting composition comprising a phase changing vehicle which is both a dielectric and a polymer and an aggregate comprising particles which will polarize in an electric field; electrically charging said conductive portions of said surfaces such that said electrosetting composition between said conductive portions of said surfaces energizes and solidifies in the manner of an electroviscous fluid, that portion of said composition between the nonconductive portions of said surfaces being unenergized and fluid; separating said unenergized portion of said electrosetting composition from said energized portion of said composition; and, maintaining said charging until said energized portion of said electrorheological composition substantially cures.

Claim 15

A process comprising: positioning an electrosetting composition between two surfaces each said surface having substantially opposite conductive and nonconductive portions, said electrosetting composition comprising a phase changing vehicle which is both a dielectric and a polymer and an aggregate comprising particles which will polarize in an electric field; electrically charging said conductive portions of said surfaces such that said electrosetting composition between said conductive portions of said surfaces energizes and solidifies in the manner of an electroviscous fluid, that portion of said composition between the nonconductive portions of said surfaces being unenergized and fluid; separating said unenergized portion of said electrosetting composition from said energized portion of said composition; and, maintaining said charging until said energized portion of said electrorheological composition substantially cures.

Claim 16

A process as described in claim 12 wherein the phase changing vehicle comprises silicone rubber.

Claim 17

A process as described in claim 12 wherein the phase changing vehicle comprises polyurethane.

Claim 18

A process as described in claim 12 wherein the phase changing vehicle comprises epoxy.

Claim 19

A process as described in claim 12 wherein the electrically polarizable particles comprise cellulose.

Claim 20

A process as described in claim 12 wherein the electrically polarizable particles comprise aluminum.

Claim 21

A process as described in claim 12 wherein the electrically polarizable particles comprise graphite.

Claim 22

A process as described in claim 12 wherein the electrically polarizable particles comprise glass microspheres.