Abstract: A method of forming a continuous composite structure includes encapsulating solid additive particles with a first reactive liquid resin forming material and migrating part of the mixture through a porous blanket to form a continuous resin matrix within the blanket with adhesive outer surfaces. A thin coating of a second preselected resin forming material which substantially cures immediately upon application is applied over one major adhesive upper surface of the matrix/blanket while allowing an area of the adhesive surface to remain exposed along one edge of the upper surface thereof. A plurality of preselected flexible lengths of the coated matrix/blanket are individually positioned successively in an overlapping orientation with the exposed adhesive area of the upper surface of the adjoining positioned length tightly affixed to the adhesive lower surface of the succeeding length to form a continuous composite structure. Also, the composite structure and apparatus for producing same.

Abstract: A method of continuously forming integrally molded structures includes the steps of rotating a plurality of independently movable multisection mold assemblies about a plurality of axes, successively flowing a plurality of polymerizable mixtures over surfaces of each enclosed mold cavity while selectively heating mold sections thereof in a preselected heating profile and monitoring the flowing of each mixture, the heating of the mold sections and the formation of resins therefrom. The monitored mixture flowing, the mold section heating and the formation of each resin are coordinated with each monitored axis rotation. The molded structure is removed after it has achieved structural integrity within the mold cavity, and the steps are repeated to form a multiplicity of the integrally molded structures on a continuing basis. Also, multiaxis molding apparatus for conducting the above method.

Abstract: A method of forming a continuous tubular structure includes preselecting a liquid reactive resin forming material, a particulate solid additive material, a porous tubular blanket and an inflatable bladder member disposed within the blanket. The additive particles are mixed with the liquid resin forming material substantially continuously to form a substantially uniform mixture thereof. Substantially all of the additive particles are encapsulated with the resin forming material. The tubular blanket/bladder combination is advanced through the liquid resin/additive mixture, part of which migrates through the blanket substantially uniformly to form a continuous resin matrix therein. The mixture-treated blanket is advanced along a preselected path, while the bladder therein is inflated to form a tubular structure of a preselected cross section. The structure is placed into a preselected final configuration while it is flexible and has an adhesive outer surface. Apparatus for conducting the above method.

Abstract: A multiaxis rotational molding apparatus includes a support portion, a molding portion and a control portion. The support portion includes an upstanding arcuate frame section. The molding portion includes an upstanding arcuate mold supporting assembly disposed within and spaced from the arcuate frame section. A mold assembly includes separable mold sections forming a substantially enclosed mold cavity carried within the mold supporting assembly. The control portion includes drive assemblies arranged in a preselected configuration adjacent the arcuate frame section selectively energized in coordination with adjacent drive assemblies for movement of the mold supporting assembly in a selected profile. Programmable memory stores preselected operating parameters. Monitors sense operating information form control components.

Abstract: Multiaxis rotational molding apparatus (11) includes a plurality of spaced generally horizontally oriented arm members (17-20) each having one end (21) extending from an upstanding frame section (22) with one mold assembly (32-35) rotatably mounted adjacent a free end thereof. Each mold assembly includes a plurality of separable mold sections (36) including plate sections (38). A plurality of movable elongated mixing chambers (47-49), each including a plurality of adjacent axially aligned rotatable driven mixing sections (52-54). A control portion (15) includes an indexing mechanism (67, 68) sequentially orienting a dispenser of each mixing chamber with each mold assembly to control formation of molded structures continuously in a preselected multiaxis molding profile. Also, a method of forming molded structures with the molding apparatus is disclosed.

Abstract: A method of and apparatus for forming a continuous structure includes the steps of preselecting a liquid reactive resin forming material, a particulate solid additive material and a porous blanket, mixing and encapsulating the additive particles with the liquid resin forming material while tumbling the materials along a cylindrical mixing chamber. The leading edge of the structure is grasped with a gripping device along its entire length and advanced over a horizontal supporting surface. Once a desired length has been formed a cutting device cuts the structure and the cut portion is placed into a final configuration while flexible and adhesive.

Abstract: A method of continuously forming an integrally molded structure in a multiaxis rotational molding operation includes the steps of rotating a multisection mold assembly (33) about at least three axes. A first freshly formed polymerizable mixture is flowed over surfaces of an enclosed mold cavity (36) within the multisection mold assembly. The flowing of the first mixture over the mold cavity surfaces and formation of a first resin (74) therefrom is monitored. A freshly formed rapidly gelling second polymerizable mixture (75) is flowed into the mold cavity to deposit a preselected quantity thereof into contact with a first preselected area of the first resin. A portion of the deposited second mixture is drawn as it is gelling toward another preselected area remote from the first preselected area to form therefrom a continuous support member (92) with structural integrity extending between the preselected areas of the first resin.

Abstract: A method of forming a continuous structure including the steps of preselecting a liquid reactive resin material, a particulate solid additive material, a porous blanket, and a thin fibrous sheet. The additive particles are mixed with the liquid resin material substantially continuously in a proportion significantly greater than that of the liquid resin material thereby encapsulating the additive particles. A pool of the resulting mixture is formed between the blanket and the sheet and the blanket and the sheet are advanced at a rate sufficient to maintain a suspension of the additive particles in the pool. Part of the liquid forming material is migrated through the blanket and the sheet in a uniform manner. An apparatus for carrying out this processing is also provided.

Abstract: A method of continuously forming an integrally molded structure in a multiaxis rotational molding operation includes the steps of rotating a multisection mold assembly about at least three axes. A first freshly formed polymerizable mixture is flowed over surfaces of an enclosed mold cavity within the multisection mold assembly. The flowing of the first mixture over the mold cavity surfaces and formation of a first resin therefrom is monitored. A second freshly formed polymerizable mixture is flowed under pressure through an orifice into the mold cavity. A liquid stream of the second mixture is formed. The liquid stream is gelled as it advances through the mold cavity to form a continuous filament with structural integrity. The filament is contacted with the first resin formed within the mold cavity. The filament is distributed over the first resin in a preselected pattern. A third freshly formed polymerizable mixture is flowed over the filament pattern formed within the mold cavity with the second mixture.

Abstract: A method of forming a continuous structure includes the steps of flowing a first liquid reactive resin forming material over a base surface, forming a first thin substantially uniform layer thereof and gelling the first layer. A second liquid resin forming material is flowed through an orifice under pressure forming a liquid stream thereof. The liquid stream is gelled to form a continuous filament with structural integrity as it advances toward the first gelled layer. The filament is contacted with the first layer and distributed thereover in a preselected pattern forming a porous non-woven filament blanket. A particulate solid material is distributed substantially uniformly over the filament blanket. A third liquid resin forming material is flowed over the blanket forming a second thin substantially uniform layer of the third liquid resin forming material and the layer is gelled.

Abstract: A method of forming a continuous structure includes the steps of preselecting a liquid reactive resin forming material, a particulate solid additive material and a porous blanket. The additive particles are mixed with the liquid resin forming material substantially continuously in a proportion significantly greater than that of the liquid resin forming material. Substantially all of the additive particles are encapsulated with the liquid resin forming material to a preselected thickness. A pool of the resulting mixture is formed on the blanket. The blanket is advanced at a rate sufficient to create movement of the additive particles within the pool and maintain the additive particles in suspension. Part of the liquid resin forming material is migrated through the blanket substantially uniformly prior to gelling of the liquid resin forming material to form a continuous resin matrix within the blanket. Also, apparatus forming the structure as well as the structure itself.

Abstract: A method of forming a continuous structure includes the steps of flowing a first liquid reactive resin forming material over a base surface, forming a first thin substantially uniform layer thereof and gelling the first layer. A second liquid resin forming material is flowed through an orifice under pressure forming a liquid stream thereof. The liquid stream is gelled to form a continuous filament with structural integrity as it advances toward the first gelled layer. The filament is contacted with the first layer and distributed thereover in a preselected pattern forming a porous non-woven filament blanket. A particulate solid material is distributed substantially uniformly over the filament blanket. A third liquid resin forming material is flowed over the blanket forming a second thin substantially uniform layer of the third liquid resin forming material and the layer is gelled.

Abstract: Multiaxis rotational molding apparatus includes a support portion, a molding portion, a mixing portion and a control portion. The support portion includes an arm member disposed in a generally horizontal orientation and having one end extending from an upstanding supporting section. The molding portion includes a mold supporting assembly pivotally connected to a free end of the arm member and an independently rotatable mold connector section. The mold supporting assembly includes a central passage therethrough from a pivotal connection with the arm member and through the mold connector section. A mold assembly includes at least two separable mold sections forming a substantially enclosed cavity. The mixing portion includes an elongated section extending axially within the central passage through the mold supporting assembly adjacent the mold connector section. The mixing section includes a plurality of deflector sections disposed along the length thereof.

Abstract: A method of continuously forming an integrally molded structure in a multiaxis rotational molding operation includes the steps of rotating a multisection mold assembly about at least three axes. A first freshly formed polymerizable mixture is flowed over surfaces of an enclosed mold cavity within the multisection mold assembly. The flowing of the first mixture over the mold cavity surfaces and formation of a first resin therefrom is monitored. A second freshly formed polymerizable mixture is flowed under pressure through an orifice into the mold cavity. A liquid stream of the second mixture is formed. The liquid stream is gelled as it advances through the mold cavity to form a continuous filament with structural integrity. The filament is contacted with the first resin formed within the mold cavity. The filament is distributed over the first resin in a preselected pattern. A third freshly formed polymerizable mixture is flowed over the filament pattern formed within the mold cavity with the second mixture.

Abstract: A method of forming a continuous structure includes the steps of preselecting a liquid reactive resin forming material, a particulate solid additive material and a porous blanket. The additive particles are mixed with the liquid resin forming material substantially continuously in a proportion significantly greater than that of the liquid resin forming material. Substantially all of the additive particles are encapsulated with the liquid resin forming material to a preselected thickness. A pool of the resulting mixture is formed on the blanket. The blanket is advanced at a rate sufficient to create movement of the additive particles within the pool and maintain the additive particles in suspension. Part of the liquid resin forming material is migrated through the blanket substantially uniformly prior to gelling of the liquid resin forming material to form a continuous resin matrix within the blanket. Also, apparatus forming the structure as well as the structure itself.

Abstract: A method of forming a continuous structure includes the following steps. A plurality of reactive resin forming materials are preselected. A first of the resin forming materials is applied over a major surface of a porous blanket in a first preselected pattern including a plurality of independent sections. A second of the reactive resin forming materials is applied over a major surface of the porous blanket in a second preselected pattern including a plurality of independent sections spaced from the independent sections of the first pattern. Substantially simultaneously, the reactive resin forming materials in the respective patterns are intermixed. A liquid resin mixture is formed over the porous blanket. The treated blanket is positioned in a preselected configuration while the blanket is deformable and adhesive. The blanket is set in that configuration. Also, the resulting continuous structure.

Abstract: A method of continuously forming an integrally molded structure in a multiaxis rotational molding operation including the steps of rotating a multimold section mold assembly about at least three axes. A first freshly formed polymerizable mixture is flowed over surfaces of an enclosed mold cavity within the multisection assembly. Flowing of the first mixture over the cavity surfaces and formation of a first resin therefrom is monitored through optical fibers extending through the mold sections. Second and third freshly formed polymerizable mixtures are flowed over resin formed within the mold cavity. Flowing of the second and third mixtures and formation of resins therefrom are monitored through optical fibers extending through the mold sections. The rotation of the multisection mold assembly is continued throughout the modling operation. Each axis rotation of the multisection mold assembly is monitored individually.

Abstract: Mobile structural unit molding and assembling apparatus includes a support portion, a raw material supplying portion, a molding portion, a unit transferring portion and a control portion. The support portion includes at least one base section with a wheeled carriage. The raw material supplying portion includes a plurality of reservoirs disposed on the base section. The molding portion includes at least one rotatable mold assembly disposed on the base section including at least two separable mold sections. A mixing chamber adjacent the mold assembly connects with raw material reservoirs through independent conduits. The unit transferring portion includes a tiltable unit positioning assembly selectively movable with respect to the molding portion. The control portion includes a programmable memory, a coordinator, sensors, actuators, a unit orienter and circuitry therefor.

Abstract: Multiaxis rotational molding apparatus includes a raw material supplying portion including a plurality of reservoirs connected independently with a mixing portion through conduits. A supporting portion includes a plurality of frame members disposed between upstanding end sections and rotatably supported thereon. A molding portion rotatably supported within the frame members includes at least one rotatable mold assembly with at least two separable mold sections. The mold sections include at least two optical fiber elements extending through the mold sections with one end of each optical fiber element terminating at a mold cavity forming surface of a mold section and an opposite end of each optical fiber element terminating at a remote second surface thereof. A signal generator disposed adjacent a remote surface end of one optical fiber element and a signal sensor disposed adjacent a remote surface end of another optical fiber element.

Abstract: Mobile structural unit molding and assembling apparatus includes a support portion, a raw material supplying portion, a molding portion, a unit transferring portion and a control portion. The support portion includes at least one base section with a wheeled carriage. The raw material supplying portion includes a plurality of reservoirs disposed on the base section. The molding portion includes at least one rotatable mold assembly disposed on the base section including at least two separable mold sections. A mixing chamber adjacent the mold assembly connects with raw material reservoirs through independent conduits. The unit transferring portion includes a tiltable unit positioning assembly selectively movable with respect to the molding portion. The control portion includes a programmable memory, a coordinator, sensors, actuators, a unit orienter and circuitry therefor.