Abstract: A multiple metallic core assembly for use in production of a plastic injection-molded component is formed by injecting molten metal alloy into a core die at a fill stage of an indexing system, indexing the core die through a cooling stage to an unloading stage, and removing the core from the core die and inserting the core in one of a plurality of locations of the core assembly. Individual cores are continued to be formed as discussed above until all the locations of the core assembly are filled, and the core assembly is complete. Therefore, the core assembly is removed and transported to a plastic molding machine to produce the plastic component. Then, the core assembly is melted out from the plastic component in hot oil, and the molten metal alloy produced thereby is returned to a molten metal alloy tank.

Abstract: Corrosion resistance of anodized aluminum surfaces is improved by conditioning the surface with a low molecular weight (2-7 carbon atoms) alcohol, and sealing the surface with long chain (10-24 carbon atom) carboxylic acid at low temperatures below about 35-50 degrees centigrade, the alcohol being a solvent for the acid.

Abstract: A method for the injection molding of a laminate article having a deformable material sandwiched between a textile layer and a thermoplastic substrate and bonded into a unitary assembly by the thermoplastic. The laminate is molded into a sheet form for deformation to a preselected shape in a die-forming operation.

Abstract: A process for forming an expanded fiber composite structure. The process includes impregnating a fiber mat with a plastic material, compressing the mat to impregnate the mat with the plastic, fully wetting each fiber and creating a substantially void-free fiber/plastic matrix, and reducing the compressive forces on the mat, allowing the fibers to rebound and expand the mat to a predetermined desired thickness, in the process creating interstitial voids. The structure is then cooled such that the plastic material stiffens and itself retains the structure at the desired thickness. The process optionally employs the addition of a molten polymeric material to the expanded or lofted mat, the material filling the interstitial voids in the structure. A composite structure may optionally be produced from a fully compressed plastic-impregnated fiber mat by heating to a temperature sufficient to loft the material and controlling the amount of lofting after the heat is applied.

Abstract: An isostatic pressurizing bag for consolidating a composite part has an outer flexible elastomer having a fixed resilient outside surface. The outer elastomer surrounds a closed chamber. A thermally expandable inner elastomer is located in the closed chamber. The inner elastomer is selected as an elastomer that can viscously flow or move in response to pressure. The outer elastomer is capable of flexure to relieve expansion of the inner elastomer. The bag is formed by curing plies of uncured silicone rubber around either a silicone gel or a particulated silicone rubber that is capable of phase change to a flowable gel in response to pressure. In use a composite prepreg is overlaid on a surface that defines the shape of a desired part. The isostatic pressurizing bag is located over the prepreg trapping the prepreg between the pressurizing bag and the surface.

Abstract: A method of molding complex composite articles having skin portions containing fibres to be injected with a resin and a core portion includes providing one or more galleries in the core or fibre skin and injecting resin into the gallery or galleries whereby it is rapidly transmitted to all portions of the skin. The galleries overcome the resistance to flow created by the capillary nature of the fibrous layer and enable more rapid mold cycles to be employed and more complex articles therefore to be molded.

Abstract: A vacuum bag including a non-porous material having impressed therein a three-dimensional pattern which defines a plurality of interconnected channels, methods for producing the vacuum bag, molding methods using the vacuum bag, and improved composite articles produced by the molding method, are disclosed.

Abstract: Sheet molded compound (SMC) charges are preheated before being molded into exterior automotive body panels using compression molding techniques under vacuum.

Abstract: A vacuum forming process, and an apparatus for carrying out the same, for imparting a predetermined shape to a sheet material. The process includes the steps of placing a thermally softened sheet material onto a molding surface of a mold and evacuating air remaining between the molding surface of the mold and the sheet material, thereby bringing the sheet material into a close contact with the molding surface of the surface of the mold. The vacuum forming process and apparatus is adapted for giving a predetermined shape to a sheet material having a low elongation ratio.

Abstract: Fiber reinforced resin composite structures are cured and fully consolidated while compensating for incomplete initial compaction of prepreg between cores, and the mandrel's thermal growth which spreads the cores apart by forming the structure around a metal alloy form fastened to a mandrel wherein the coefficient of thermal expansion of the metal alloy is greater than that of the mandrel.

Abstract: The invention relates to a method and apparatus for bringing together a mixture comprising a basic liquid product and a hardener with a view to attaining a fast-hardening product for spraying a surface characterized in that upon the interruption of the spraying, a circuit for adjusted delay is activated for a period of time between a zero value and a value at least slightly less than the hardening time of the hardener when air-sealed. At the end of the predetermined period of time delay, with the aid of this delay circuit, a signal is emitted, the signal is operatively applied to circuits to cause the feeding of the base and hardener (2) to the mixer to be interrupted while an evacuation and cleaning cycle is triggered. This cycle includes, in particular, alternating phases of washing, using at least one solvent, and rinsing. During the cleaning cycle, the hardener is returned to its reservoir by way of a recirculation circuit.

Abstract: A cast mold and process for casting a substrate for an information recording medium has an uneven preformat pattern formed on the mold surface. The uneven preformat features a pattern corresponding to tracking grooves and information pits, each information pit portion has a size with a length b in the direction parallel to the pattern of the tracking groove of 2 to 15 .mu.m and a width a in the direction perpendicular thereto of 1 to 6 .mu.m and a height c of 300 to 3500 .ANG.. The pit pattern has a pitch which is 1.8-fold or more of pit length b.

Abstract: A method for rapidly forming composites by rotating an alterable male mold to wrap a plurality of continuous and intermittent layers of uncured laminate around the male mold when in a closed position and allowing the male mold to be moved into a female mold and to thereafter sever all layers on the male mold into an open position which thereafter transfers the resin matrix composite to a female mold which shapes the composite in a desired configuration and thereafter heat cures the composite lay-up material while being subjected to a vacuum. A second embodiment of the invention uses a non-rotatable male mold.

Abstract: A process for fabricating a composite article is disclosed. A surface of a preconsolidated fiber reinforced glass matrix composite structure is pretreated to promote adhesion to the surface, a mass of fiber-containing uncured resin is molded in contact with the pretreated surface and the resin is cured to consolidate a fiber reinforced resin matrix composite structure and simultaneously bond the resin matrix composite structure to the glass matrix composite structure. A composite article fabricated by the above process is also disclosed.

Abstract: A modular mold system for making molds in a range of incrementally different sizes is provided as is a method for using that system in the manufacture of containers. The mold system includes corner elements, edge angle elements and spacer elements which can be interlocked together through connecting means to form a mold for a container. The boundaries of each mold element are defined by straight lines meeting at right angles and each mold element has at least one common dimension with every other element. The mold system is particularly adapted for use in making fiberglass reinforced products such as insulated containers having an inner shell and an outer shell with insulation between the shells.

Abstract: Apparatus for producing press-molded articles having a plurality of cavities therein includes a mold cavity which can be filled with a particulate molding compound, which mold cavity contains rods sheathed with expandable tubes which can be expanded by means of a fluid under pressure conveyed into the space between the rods and the tubes: this causes compaction of the molding compound to form the pressed article, which can be removed from the mold after reduction of the fluid pressure to allow detumescence of the expandable tubes and withdrawal of these from the mold cavity so that the mold cavity can be opened to remove the shaped pressed article.

Abstract: A method for molding an article integrated with a multi-layer flexible circuit by embedding the circuit in a molding material to be shaped into a certain configuration. A first flexible circuit layer is sandwiched between a fixed mold and a movable mold so as to perform an injection shaping of one side of the molding material. A plurality of flexible circuits from the second layer of flexible circuit and subsequent flexible circuits are sequentially sandwiched between the fixed mold and the movable mold and they are layered one on the other. The movable mold contains a heater. The pattern of each flexible circuit is traced with thermosetting conductive paste which is hardened by the heater of the movable mold when flexible circuits are laminated on each other. Each flexible circuit has a hot-melt type adhesive layer on the rear surface thereof.

Abstract: A process is disclosed wherein two co-reactive resin streams are mixed immediately adjacent the entrance of an impregnation die used to make products by the pultrusion process. The mixing occurs immediately adjacent the fibers as they are pulled into the central duct opening of the die. The resin streams are delivered to the entrance of the impregnation die by use of a resin feed head positioned at the inlet of the impregnation die. An ultrasonic driver coupled to the resin feed head vibrates and agitates the resin streams impinging the fibers so as to thoroughly wet the fiber bundle prior to its passage through the die.

Abstract: Process for manufacturing tubes of a composite material from a preimpregnated fibrous reinforcing sheet whose width is split into a strip portion and a casing portion, where the thickness of the sheet is slit in the casing portion. A mandrel is inserted into the casing portion and rotated to cause the strip portion to be rolled around the mandrel, and the rolled strip and mandrel are placed into a plastic case for cross-linking. The process can be applied to the manufacture of tubes of small diameter, such as fishing rods, golf clubs and boat masts, and to the manufacture of porous tubes for use as a filtering material or filter membrane support.

Abstract: Methods for treating metal surfaces including contacting the surface with a water soluble or water dispersible polymer comprising a repeat unit (a) having the structure ##STR1## or salt form of said repeat unit, wherein R and R.sub.1 are the same or different and are independently chosen from C.sub.1 -C.sub.3 lower alkylene and wherein z is an integer of from 1-3. The methods also include use of copolymers having in addition to repeat unit (a) above, a repeat unit (b) having the structure ##STR2## from wherein X is OH, NH.sub.2, or OM wherein M is a cation, the molar ration of (a.sub.1):(b) being present in said copolymer being from about 20:1 to 1:20. The methods provide chromium free rinse solutions for use in rinsing phosphate-based conversion coated metal surfaces.