Abstract: A method of manufacturing a plurality of interconnected vials with a mold. The mold includes a first slide and a second slide. The method comprises contracting the first slide and the second slide so that a plurality of cavity profiles linked together by a plurality of arms is formed. A plurality of core pins is placed within the plurality of cavity profiles so that the core pins are freestanding. A plastic fluid is injected about the plurality of core pins to form a plurality of interconnected vials. The plurality of interconnected vials are removed from the plurality of core pins. The plurality of interconnected vials are placed into a holder tray and a liquid is injected into the vials. The open ends of the vials are heat sealed in order to encapsulate the plurality of interconnected vials. The steps of heat sealing include applying heat, measuring the temperature applied, and measuring the time the heat is applied.

Abstract: The inventive method concerns a process of transferring resin into reinforcing fiber material used in the manufacture of composite articles. A first step in the method involves positioning at least one layer of the reinforcing fiber material on the surface of an open mold. The reinforcing fiber material typically consists of glass, carbon, linear polyethylene, polypropylene, and polyester fibers. Subsequently, a sealant layer is applied in liquid form over the reinforcing fiber material to create an airtight chamber encapsulating the reinforcing fiber material between the sealant layer and the mold. After the sealant layer is allowed to cure, a vacuum pressure is applied to the airtight chamber to draw resin through the reinforcing fiber material. For example, the resin can be an epoxy, polyester or vinyl ester resin.

Abstract: A method of moulding articles from layers of composite material being fibres impregnated with uncured resin, includes draping at least one layer of the composite material over a moulding tool, applying over the composite material layer or layers a membrane, and establishing an at least partial vacuum between the membrane and the moulding tool to consolidate the composite material, and wherein the membrane is made of a resilient material, and the method includes applying a force to the membrane to stretch the membrane over the moulding tool and maintaining the force whilst the at least partial vacuum is established.

Abstract: A method of making a composite part includes the steps of placing a first section of a fibrous pre-form in a mold and infusing the first section of the fibrous pre-form with a resin so as to produce a resin-infused portion and a non-resin-infused portion. Next, the method includes coupling the non-resin-infused portion to a second section of the fibrous pre-form to create a coupled non-resin-infused portion. Then, the coupled non-resin-infused portion is infused with resin to create a second resin-infused portion and a second non-resin-infused portion. These steps are repeated to separately infuse different sections of the part until the part is complete. The corresponding apparatus preferably employs a rigid mold having a shape defining only a portion of the composite part to be made. And, the method is particularly adapted to making both cored and non-cored structures that are large or unconventionally shaped.

Abstract: A closed mould method of producing composite mouldings is provided. A sensor system (4, 5, 6, 7, 8) is provided for sensing distortion of one (1) of the mould elements while the resin mix is being fed into the mould cavity. A signal is generated if a predetermined degree of distortion is sensed.

Abstract: A rotomolded plastic wall and ladder structure (10, 50, or 58)), which may be an article such as a window well (10) or a manhole (50 or 58), includes a thermoplastic wall (12), a ladder (16) whose rungs (18) each include an elongated metallic core (20) and a thermoplastic sleeve (22). Mold apparatus (70) includes a thermoplastic rotomold (72), an elongated hollow metallic core (20) having a heating passage (74) therein, and means for flowing hot air through the heating passage (74). The method includes disposing the hollow metallic core in a mold, placing a quantity of a thermoplastic inside a mold, heating the mold, rotating the heated mold, flowing heated air through the hollow metallic core, and bonding a layer of the thermoplastic onto the hollow metallic core.

Abstract: A method for injection molding a plastic applicator with a ball of bristles produced integrally with a support handle. The mold consists of two opposing parts. The mold is machined by means of a laser. The mold is laser drilled with gradually decreasing depths of bores from the midpoint of the mold parts outwardly.

Abstract: A molding process that uses a textured interfacial layer to isolate the surface of a mold from the surface of a composite article produced with the mold. A solution is deposited on the mold surface to form the interfacial layer, whose surface opposite the mold is textured. The texture of the interfacial layer is then transferred to the surface of the composite article produced with the mold. After demolding, the interfacial layer adheres to the article as a protective coating, but can be readily removed from the article to expose an underlying textured surface of the article.

Abstract: A maskless patterning apparatus allows for laser beam ablation of one or more layers of material while not etching an underlying different material layer. A micromirror array produces the desired complex pattern on the workpiece and a continuous feature and end point detection system provides location and material parameter changes to accurately control the pattern position and depth of etching. End point detection includes monitoring energy reflected from a specially prepared replica of the material to be ablated, whose thickness and consistency match the active workpiece area. The process terminates when the proper amount of material is removed.

Abstract: A method for producing a composite component having a variable thickness includes placing a caul member over a plurality of laid-up prepreg plies supported by a mold. The mold includes a cavity for receiving the lay-up that is defined by a bottom surface, a plurality of walls extending upwardly from the bottom surface, and an open upper face surrounded by a mold edge. A support flange extends inwardly toward the center of the cavity from each of the walls at a predetermined distance from the bottom surface. The caul is made from an anisotropic material so that the caul is basically rigid about lateral axis and flexible about a longitudinal axis. During an autoclave curing process, the caul applies pressure along the length of the lay-up to draw the caul into engagement with the support flange, which serves as a stop to prevent further movement of the caul.

Abstract: A process is provided for manufacturing an imbedded flooring product having a skeletal frame in the form of a mesh at least partially imbedded into a vinyl sheet substrate. The method provides for the mesh to create a pattern visible from above the sheet.

Abstract: There is presented a method of connecting a plurality of mandrels to one another to constitute an integral mandrel 10, forming a fabric 1 on the surface of the integral mandrel, and infiltrating the formed fabric with matrix. A plurality of products can simultaneously be manufactured, and this can remarkably reduce fiber loss and enhance productivity.

Abstract: Composite structures having a single continuous skin may be formed using automated fiber placement methods. These composite structures include frameless aircraft fuselage components offering an increased interior cabin width over conventional fuselage components. The composite structures may be constructed of multiple layers of fibers and other materials placed on a fiber placement tool that includes a mandrel body surrounded by a bladder or an integral bladder/caul sheet having expansion spaces created within the caul sheet section. Uncured composite structures may be created by placing fibers around the fiber placement tool in a plurality of discontinuous segments that are capable of moving or sliding in relation to each other so that the uncured composite structure is expandable from within.

Abstract: A colored substrate is positioned between a material and a laser, and the material is scribed with a laser that has been directed through the colored substrate. By so doing, color is transferred to the material to form the color graphic without undesirably carbonizing, melting or burning through the material. The energy density per unit time can be defined as continuous power divided by the area of the spot and the speed.

Abstract: A method for making rotationally molded objects using resin blends. The resin blend comprises resin pellets and an amount of ground resin powder sufficient to yield rotomolded objects having desirable impact strength and other strength characteristics. Preferably, the resin blend comprises of from about 20% to about 40% by weight of ground resin powder. The resin pellets may optionally contain a reinforcing agent. In addition, resin blends can be used to produce colored objects by rotational molding techniques.

Abstract: A three-dimensional object is manufactured by filling and hardening a powder material around a core. A powder material is first filled and layered around the core, and a beam is then selectively irradiated on the layer of powder material to form a hardened layer united with the core. These steps are repeated to form a plurality of hardened layers around the core, thereby manufacturing the three-dimensional object having the core embedded therein.

Abstract: A method and system for molding thermoplastic sandwich material to form a deep-drawn article utilizing a unique clamping technique and mechanism are described. The method includes the steps of positioning a blank of thermoplastic sandwich material having a cellular core over a female die having an article-defining cavity defined by inner surfaces of the female die. Then, an inner portion of the blank is forced into the female die along a substantially vertical axis and against the inner surfaces of the female die to obtain deep-drawn material. During the step of forcing at least one outer portion of the blank immediately adjacent the female die is clamped to guide the at least one outer portion of the blank to travel into the article-defining cavity at an acute angle with respect to the vertical axis. Thickness of at least one side wall of the deep-drawn material is substantially the same as thickness of the blank of thermoplastic sandwich material.

Abstract: A method and system for co-molding a thermoplastic material with a thermoplastic sandwich material to form a thermoplastic sandwich article having a thermoplastic inner portion are provided. An inner male die forces the thermoplastic composite material and the sandwich material within the peripheral edge portion together at a temperature and pressure sufficient to fuse the materials together to form a thermoplastic composite inner portion of the sandwich material.

Abstract: An improved pipe belling process is shown which features a mandrel having a specially designed backup or forming collar. The backup collar has an exposed lip portion which forms a complimentary angle with the outer sloped surface of the gasket which it abuts. The complimentary angles of the backup collar and gasket form a wedge shaped contact area which serves to retain the gasket in its initial circumferential position on the working surface of the mandrel as the heated pipe is forced over the mandrel and gasket.

Abstract: A method provides for full or partial infusion of resin into three-dimensional, woven textile preforms. Resin film is placed at selected locations adjacent the preform, and the resin film may be separated from other areas of the preform using separator sheets or other materials. The preform is heated and may be vacuum-bagged to apply pressure, or may be rolled or fed through a die. The heat and pressure cause the resin to infuse into the selected areas of the preform adjacent the resin films. The amount of resin in the partial infusion is the same as is necessary to fully infuse the preform, but the resin remains localized in the selected areas until heated again at cure to cause the resin to flow throughout the preform. The method may also be used to fully infuse the preform with resin by providing sufficient temperature and time at that temperature during the initial infusion.