Abstract: The invention is a process for forming a 3D woven PI shaped cross-section preform having a first and second bottom foot portions and first and second upstanding leg portions for use in a structure having at least one curved portion of a specific length. In detail, the process includes the steps of: 1) cutting the treads parallel to the direction of curvature into over a length equal to the length, such that the cuts in each thread are spaced from the cuts in the adjacent treads; 2) stretching the portions of the preform requiring curvature; and 3) forming the curvature in the preform.

Abstract: A composite formed of a polymer matrix phase having a reinforcement phase including polymeric microfibers. The microfibers are preferably formed of a highly oriented polymer, having a high modulus value and a large surface area. The large surface area can serve to tightly bind the microfibers to the polymer matrix phase. The microfibers can be provided as a fully- or partially-microfibrillated film, as a non-woven web of entangled microfibers, or as a pulp having free fibers. The microfibers can be embedded in, or impregnated with, a polymer or polymer precursor. Some composite articles are formed from thermoset resins cured about a highly oriented polypropylene microfiber reinforcement phase, providing a strong, tough, moisture resistant article. One composite includes a matrix and reinforcement formed of the same material type and having substantially equal refractive indices, allowing the composite to be optically clear.

Abstract: An improved double wall tank has two or more threaded fittings, with a steel outer tank and a thermoplastic inner tank. The inner tank is formed within the outer tank by rotational molding. The inner tank is bonded to the outer tank in an area of the fittings, but is otherwise separate and apart from the outer tank. Before carrying out the rotational molding process, bonding material is applied to the outer tank in the area of the fittings. The thermoplastic material is in powder form and includes mold release material. The thermoplastic material is inserted into the outer tank before rotational molding. The degree of shrinkage of the inner tank can be controlled by air pressure including an area between the fittings.

Abstract: A process of inlaying a design in a fiberglass article to provide a decorative article of manufacture. The process comprises applying a first lamina of releasing agent into a mold. Then forming a second lamina of clear gel coat on the first lamina and allowing it to dry. Then forming a third lamina of transparent polyester resin on the second lamina and submerging the design into the third lamina before the third lamina is dry. Then removing air bubbles from the design and the third lamina and allowing the third lamina to dry. Then applying a fourth lamina of curable resin on the third lamina, whereby the fourth lamina is formed substantially from fiberglass of a white pigmentation, and allowing it to dry. Lastly, removing the mold from the first, second, third, and fourth laminas.

Abstract: A method of making golf club grip includes the steps of overlapping a textile fabric on a first raw rubber layer and painting a rubber latex on the textile fabric to attach the textile fabric on the first raw rubber layer to form a thin reinforced rubber layer laminated with the textile fabric; preparing a second raw rubber layer which is shaped and sized to form two control members; shaping the first raw rubber layer to form two anti-slip members; aligning the anti-slip members with the control members in an end to end manner in two halves of heat mold respectively; and vulcanizing the anti-slip members and the control members in a heat mold to form the golf club grip including a tubular anti-slip arrangement and a tubular control arrangement coaxially extended from a lower end of the anti-slip arrangement.

Abstract: A method of manufacturing a row of encapsulated interconnected vials with the mold. The method includes forming a plurality of cavity profiles linked together by arms, and inserting a plurality of core pins into the cavity profiles. The method includes injecting a plastic fluid about the core pins to form a row of interconnected vials. The method includes removing the row of interconnected vials and positioning the row into a holding tray. The method further includes placing the liquid into the row of interconnected vials with an injection device. An open end of the row of interconnected vials is heat-sealed. The step of heat-sealing may include applying heat, measuring the temperature, and measuring the time heat is applied.

Abstract: A method for manufacturing carbon-carbon composites includes steps of producing a mat using carbon fiber, carbon fabric, carbon sheet, or staple fiber; laminating at least three layers of mats; producing a preform using the laminated mats with a needle punching method; performing a first thermal treatment process on the produced preform at a predetermined temperature; densifying the first-thermal-treated preform; performing a second thermal treatment process on the densified preform; forming a predetermined shape out of the second-thermal-treated preform; and performing an oxidation resistant treatment process of the shaped preform.

Abstract: The method of making a tubular member having a continuous and uninterrupted cured elastomeric resin coating on an outer surface of the member includes forming a continuous uninterrupted tubular layer of uncured elastomeric resin and drawing the resin layer against the surface of the tubular member to be coated by applying suction between the resin layer and the surface of the tubular member so that the resin adheres to the surface of the tubular member. The elastomeric resin may then be cured to produce the final product. Apparatus for carrying out the process includes, in sequence, a coating zone including a sub-atmospheric chamber, a heating zone and a feed mechanism for advancing the tubular member relative to the coating and heating zones. A method includes molding a distal end cap on an open end of a length of a preformed tubular sleeve member that may be used for prosthetic applications.

Abstract: A device for the identification marking of a workpiece which is made of a deformable material. The workpiece identification marking has a plurality of identification elements, each of which comprises elevations that project out of the surface of the workpiece. For each of the plurality of identification marking elements there is an opening in the workpiece identification marking mold of the device, through which thermal radiation can be applied to the surface of the workpiece to generate an image point, so that material that extends through the opening extends into the opening.

Abstract: A method for manufacturing of water-proof cover for zipper tab includes taking a zipper where holes are provided on the tapes thereof at the position adjacent to one end of the tooth-chains; covering an upper mold provided with a sprue thereon and a lower mold on the holes on the tapes, and inserting a core mold in-between the groove and tooth-chains; injecting plastic from the sprue and detaching the upper and lower molds after the plastic is solidified to a desired shape, such that a decorative cover is formed at one end of the tooth-chains; and mounting a zipper tab from the upside of the tooth-chains, and stapling a stopper to each end of the combined tooth-chains. Accordingly, when the zipper is drawn upwardly, the zipper tab can be positioned inside the decorative cover, such that the connecting portion of the tooth-chains and the zipper tab can be covered by the decorative cover and therefore prevent from being wetted by rain.

Abstract: A method of making a polishing pad having a body comprising fibers embedded in a matrix polymer formed by a reaction of polymer precursors. The fibers define interstices, and the precursors fill these interstices substantially completely before completion of the reaction. The method comprising placing the fibers and the precursors in a cavity of a mold for shaping the polishing pad; applying a differential pressure across a mold cavity, where the differential pressure and the amount of precursors are sufficient to cause the precursors to fill the interstices substantially completely before completion of the reaction; and applying sufficient heat to the mold to at least partially cure the polishing pad by causing the precursors to react.

Abstract: A multi-layer rotational-molded plastic article has an area, such as a sight line for viewing content levels, where an inside layer protrudes through the outside layer and may be bonded to it. A first flowable material such as plastic resin is introduced into a mold having an insulating member extending through an aperture or slot into the mold. The mold is rotated and heated to less than full cure. The insulating member is removed, a second, transparent flowable material is introduced into the mold, and a cover member replaces the insulating member. The mold is rotated and heated to cure both resins, and only then cooled and opened.

Abstract: A manufacturing system and method for use in the production of high strength plastic materials which can be used in the construction arts. The system and method includes a central rotary mold element which has vacuum means and cooling means placed inside thereof. Heating elements are positioned exteriorly of the rotary mold. Treated long fiber sheets are introduced to the rotary mold and combined with plastic sheets which are also fed to the mold.

Abstract: A method of fabricating a damage tolerant shaft is provided in which a plurality of lobes are initially formed and are then positioned relative to one another to define an annular body and a plurality of ribs extending within the annular body. The plurality of lobes are formed of a plurality of reinforcing fibers extending at least partially about a respective lobe. Once the lobes have been positioned relative to one another, interstices between portions of adjacent lobes may be filled. Additionally, the plurality of lobes may be surrounded by an outer layer, also formed of reinforcing fibers extending at least partially about the plurality of lobes. The plurality of lobes may be impregnated with resin and cured, either prior to being positioned relative to one another or thereafter.

Abstract: A unitary two component article for personal hygiene, as a toothbrush, wherein the same is formed by injection molding of two differing plastic materials, which plastics do not adhesively or chemically bond to each other, thereby facilitating the manufacturing process. The two differing plastic parts of the toothbrush are mechanically connected, as by interfitting portions of the two plastic components and as by shrinking one plastic component about the other.

Abstract: A method for fabricating a protective helmet includes the steps of: (a) providing a fiber-based filler, such as a fiberglass sheeting; (b) mixing course ceramic particles into a thermoset resin; (c) impregnating the resin/ceramic particle mixture into the fiber-based filler; (d) forming or molding the impregnated fiber-based filler into a shape of a protective helmet; and (e) curing the resin mixture impregnated into the fiber-based filler. The course ceramic particles are preferably created by chopping a ceramic material. The presence of the ceramic particles in the composite helmet substantially reduces the heat reflectance of the helmet; while also reducing the overall weight of the helmet, since the ceramic material weighs less than the portion of resin material that the ceramic material is being used in place of. Finally, because the ceramic particles are course, they will not all flow to “low spots” in the helmet during the curing process.

Abstract: A variety of hollow structures with unique morphologies were manufactured with a rotational spinning technique. Phase separation of soluble solutions or emulsions was induced within a filled mold as it was being rotated about one of its axis. The density difference between phases results in sediment at the inner lumen of the mold under centrifugal forces. After or during sedimentation, gelation of the phase-separated particles fixes the hollow structure morphology and the solvent remains in the center of the mold. The solvent is removed from the mold resulting in a coating or tube. By controlling the rotational speed and the formulation chemistry, the tube dimensions and wall morphology can be manipulated. This technique offers a new approach to the manufacture of polymeric tubes. It requires small quantities of starting material, permits multi-layering of tubes, is applicable to diverse polymers and can result in highly diffusive hollow structures while maintaining good mechanical strength.

Abstract: A multilayer plastic substrate. The substrate comprises a plurality of thin film layers of at least one polymer, the plurality of thin film layers being adjacent to one another and having sufficient strength to be self-supporting, wherein the multilayer plastic substrate has an average visible light transmittance of greater than about 80%.

Abstract: Improved dip coating methods and mandrels for forming polymer leaflets and valve prostheses generally involve one or more features on the mandrel that facilitate the processing. The mandrel has a top surface and an outer surface comprising a plurality of ridges and contoured surfaces extending to the ridges. An edge on the mandrel separates the top surface and the contoured surfaces, with the mandrel edge corresponding to the free edge of the leaflet. In preferred embodiments, the edge separating the top surface from the contoured surfaces is sharp. The polymer formed on the top surface can be efficiently separated from the remaining portions of the polymer structure to form the free edges of the leaflets.

Abstract: The invention is an apparatus and a method for drilling holes in a work piece with a laser. A laser beam is received by the optical system and directed along an optical path. The system directs the laser beam through a moveable mask aperture creating a sub-beam, that is reduced in size by a lens system as it is imaged onto a work piece. Multiple features are formed in the work piece by moving the mask.