Abstract: Composite prepreg is laid up over a tool by placing prepreg material on a carrier film and using the carrier film to apply the prepreg material to the tool. The prepreg is conformed to contours of the tool by deforming the carrier film.

Abstract: A method for producing diaper component parts (3) from strip material (5, 8), wherein the strip material (5, 8) is fed continuously, by means of conveying means (6), along a straight path (P) extending through a number of work stations (9, 16, 21) synchronized with one another; and wherein, along the path (P), the strip material (5, 8) is secured to the conveying means (6) so that all points of the strip material (5, 8) travel at the same speed.

Abstract: A method for manufacturing an elongate stiffening element and a rigid shell structure integrated with at least one elongate stiffening element. The method includes providing a preformed, form-stable reinforcement member, which has a hat profile with two inwardly directed, opposing flange portions, covering the reinforcement member with a curable composite material to form an external hat profile having outwardly directed flanges, and integrating this assembly with either a curable or preformed shell structure of composite material.

Abstract: The invention is directed to a process for the making of a product out of laminated composite material. The process in general comprises preforming at least one layer of material such that it corresponds to a surface of a part; applying layers of fibers to the preformed layer of material; and bonding the fibers by a resin to form a laminated composite material.

Abstract: A three-dimensional filter includes a filter frame having a three-dimensional skeletal structure with a filter media connected to the skeletal structure. The filters are nestable. The skeletal structure may be trimmed and provided with walls to create standard sized filters. Methods for making the three-dimensional filter include injection molding of the skeletal structure onto the filter media, injection molding the filter media and the filter frame together in a single molding process, thermoforming a molded or extruded skeletal structure and the filter media, and needle punching a molded or extruded skeletal structure to create filter media within the skeletal structure.

Abstract: The tile installation system provides a system for installing an architectural covering material to a substrate surface utilizing a plurality of release sheets where each release sheet has a top side surface and a bottom side surface. A plurality of discrete adhesive substrate portions are positioned on the top side surface of the release sheet, wherein the top side surface of the release sheet has a stronger bonding affinity with the plurality of adhesive substrate portions than the bottom side surface.

Abstract: Disclosed is an airfoil comprising a plurality of ceramic matrix composite (CMC) fabric sheets which are layered to form a single, layered fabric sheet. The layered fabric sheet is formed so as to define a pressure and suction side of the airfoil. The airfoil includes primary fibers which extend radially outwardly from a rotor disk, for example. In this way, the airfoil is suitable for use in a gas turbine engine due to the temperature resistance of CMC and the strength provided by the primary fibers.

Abstract: The present invention is a method to manufacture shaped foam composite articles and articles made therefrom. Specifically, shaped foam articles having a laminated skin such as a solid thermoplastic sheet. The shaped foam article (10) and the skin may be made from the same or different materials. The method comprises (i) preparing a shaped foamed article with a plurality of perforations and (ii) vacuum forming a skin onto the perforated shaped foamed article.

Abstract: A method of manufacturing a multi-layer outer panel for a game ball includes three-dimensionally forming a top layer of an outer panel, as well as one or more backing materials disposed underneath the top layer, into a shape substantially corresponding to the surface of the ball. Multi-layer outer panels are then attached to or interconnected to surround an inflatable bladder, thereby producing a game ball while minimizing overstretching of the outer material or the backing material and improving resistance of the outer panels to delamination.

Abstract: An insulating material is fed in and shaped by superposing a plurality of N layers Ci (3) of the insulating material. For each layer Ci, a plurality of ni, axial insulating elements Ei precut from the insulating material is formed, a rough form of the tubular insulating device is formed by using an adhesive to assemble the Ni elements Ei of each layer Ci which are juxtaposed along a plurality of joining zones Ji, so that the plurality of joining zones Ji+1 of a layer Ci+1 is offset relative to the plurality of joining zones Ji, of the adjacent layer Ci. Then, by the adhesive is polymerized, and the tubular element rough form is subjected to a heat treatment. The method is economical and makes it possible to obtain a device of high mechanical strength.

Abstract: A jet vane for use in streams of hot gas, comprising a wing having a core area and a cover skin area surrounding the core area, is proposed. The cover skin area is made of a fiber-reinforced material, and the fibers in the cover skin area are oriented substantially parallel to the wing surface, and/or the cover skin area is made of a fiber-reinforced material that is reinforced with short fibers.

Abstract: The present invention provides a laminate stair tread a core having a top surface and a bottom surface, and opposing read side and front side, the front side being substantially curved, and a laminate layer affixed to the top surface of the core including the curved front side, thereby providing a flat, unobstructed, and seamless surface.

Abstract: A prosthetic medical device is formed by the combination of a biological tissue a shape memory polymer structure. The biological tissue provides an in-situ physiological function of the device. The shape memory polymer provides a capability for minimizing the device profile during insertion and then deploying after placement into a memory shape that achieves suitable mechanical structure and stability within an anatomical lumen or cavity. This configuration may be applied to form various prosthetic devices including aortic, mitral, and tricuspid valves in the heart; venous valves; anti-reflux valves for the lower esophageal sphincter; and other biological valve structures. Alternatively, an entirely non-biologic implementation using only shape memory polymer-based structures may be used as a prosthetic valve device.

Abstract: To improve heat generating efficiency and printing quality, a plurality of heating resistors (14) are arranged with spaces therebetween on a heat storage layer (13) laminated on a surface of a supporting substrate (11) via an adhesive layer (12) made of an elastic material. A cavity section (19) is formed at a region between the supporting substrate (11) and the heat storage layer (13), the region being opposed to a heat generating portion of each of the plurality of heating resistors (14). The cavity section (19) includes a concave portion (20) formed in the surface of the supporting substrate (11) and the heat storage layer (13) in which the concave portion (20) is closed and the surface thereof is exposed to the cavity section (19).

Abstract: A reflective sheet material for use on exterior signs and exposed surfaces includes a sheet member having a series of adjacent, parallel primary grooves extending across at least one surface. Each group is defined by first and second elongate facets forming an angle of at least 90 degrees in a plane perpendicular to the surface and to the length of the facets. A thin opaque, reflective layer extends over the surface in the region of the grooves and conforms to the series of grooves so as to form a series of associated angular grooves. A transparent material extends over and substantially fills these angular grooves, thereby forming a substantially smooth outer surface which is located at or close to the top edges of the grooves. The sheet material can be flexible or rigid.

Abstract: A method of manufacturing a film waveguide includes molding a first clad layer formed with a concave groove for core filling, molding a second clad layer, and laminating the surface formed with the concave groove of the first clad layer and the second clad layer using resin. The resin has a flexural modulus of smaller than or equal to 1,000 MPa, contains hydrogen bonding group in a functional group of a precursor, and has a refraction index higher than the clad layers. A core is formed in the concave groove by the resin.

Abstract: The invention relates to an improvement for applying a layered structure (1) onto a convex surface of a lens (10). After thermoforming the layered structure, a curvature direction of the layered structure is inverted. The structure is then applied on the lens surface by continuously pushing the structure (1) against the lens surface, starting from a contact point between a convex surface of the structure and the convex surface of the lens. The curvature direction of the layered structure is then inverted again, so that it recovers the curvature direction that resulted from thermoforming. Stresses within the layered structure are then reduced, and the structure can be assembled with the lens without defects.

Abstract: The present invention relates to a process for manufacturing composite ring frames for aeronautical fuselages by means of the application of the RTM technology to two preforms with C- and L-shaped sections manufactured using two tools (21, 55) in the following steps: providing the material; hot-forming planar rectangular laminates (41); hot-forming laminates of right angle section (51) on one part of right angle section of the first tool (21), placing an elastic membrane (55) and applying a temperature and vacuum cycle; hot-forming the preforms into a C shape (11) and L shape (13) on a second curved tool (55) by deforming said laminates of right angle section (51) thereon, and applying a temperature and vacuum cycle. The invention also relates to said tools (21, 55).

Abstract: A method is provided for fixing a silicone gel component, including a step of contacting the gel component with a sheet made of microporous material, such that the silicone gel is attracted upon contact with the sheet, thereby forming an assembly in which the component is fixed to the sheet without glue or adhesive. The method is applicable to the production of modules for protecting a human body part, in particular the foot.

Abstract: A soundproofing assembly includes stacked layers in the form of a first set of layers (36) having good resistance to the passage of air, and a second set of layers (24) with mass-spring function including a layer (28) having a heavy viscoelastic mass and a spring type layer (26); the first set of layers includes a layer (36) of a foam with open cells of high porosity, high tortuosity and good resistance to the passage of air, the layer (36) having, owing to its high tortuosity, excellent sonic absorption properties at medium and high frequencies. The invention is useful for soundproofing motor car passenger compartments.

Abstract: A process for placing elements of a self-stiffened panel of preimpregnated composite. The panel includes a base skin and a plurality of U-shaped stiffeners, with an interfacing structure including a nail and a nail-head. The process includes draping plies to form the base skin; placing and shaping at least one reinforcing ply on a set of punches; forming half-nails; placing a half-nail on the sides of each punch covered by the reinforcing ply; positioning the punches side by side in inverted U-positions; placing the nail-heads; compacting the set of punches; turning the punches 180 degrees; positioning the set of punches on the base skin; and withdrawing the set of U-shaped punches.

Abstract: A heating element that can be incorporated into a molded foam article closely adjacent to the outer cover sheet without showing any evidence that a heating element is encapsulated within the foam portion of the article and provides essentially the same relatively softness and “feel” that would be obtained if the heating element was not part of the article.

Abstract: A method for covering a flower pot with a sheet of material or a pot cover. At least a portion of a sheet of material, or the inner surface of the pot cover and/or the outer surface of the flower pot is provided with a bonding material such that upon wrapping the sheet of material about the outer surface of the flower pot or placing the flower pot in an interior space of the pot cover, the flower pot is secured to the sheet of material wrapped thereabout or the pot cover via the bonding material.

Abstract: A method of making a vehicle interior trim part includes forming an air-permeable substrate into a desired shape; positioning the formed substrate and a cover material on a vacuum mold such that the substrate extends between the cover material and the mold; and vacuum forming the cover material over the substrate.

Abstract: This invention relates to the fabrication of veneer faced panels (10), in particular veneer faced panels (10) for mounting in the passenger compartment of a motor vehicle. A blank (14) is shaped and trimmed by placing it in a first press (20) having a tool with a flat peripheral pressing surface (30) and then placed in a second press (40) also having a flat peripheral pressing surface (31) following which a layer of veneer (16) is placed over the blank (14) before being pressed against the blank (14), so that a veneered panel (10) is formed with flat and parallel end face (18).

Abstract: The vehicle seat of the invention includes a cushioning material having a ridge surrounding and defining a seating area on the cushioning material and a skin material covering the cushioning material. The skin material and cushioning material are bonded together only within the seating area. The skin material is a laminate including, in succession, a PVC layer, a knitted fabric and a closed-cell synthetic resin foam. A water proof film may be interposed between the cushioning material and the skin material outside of the seating area.

Abstract: A method for adhesively bonding a covering to a support using a dry heat-sensitive adhesive to produce an assembly for an automotive interior. The method positions the layers to form an assembly of material layers in tooling that concentrates microwave radiation energy conversion to the adhesive layer above its melting temperature. The method for fabricating an assembly in accordance with the subject invention, particularly when the tooling is transparent to the radiation, controls the radiation reflection, which is generated at a frequency exceeding 30 GHz.

Abstract: A production method of an absorbent body is provided. The method includes the steps of: supplying a first cover sheet on an outer surface of a rotating pattern drum, said pattern drum being provided with a concavity formed in a predetermined shape on the outer surface thereof; adapting the first cover sheet to the shape of the concavity and supplying an absorbent material into the concavity to form an absorbent material layer adapted to the shape of the concavity on the first cover sheet; supplying a second cover sheet toward the outer surface of the pattern drum; and separating the first cover sheet together with the absorbent material layer from the outer surface of the pattern drum and superposing the first cover sheet together with the absorbent material layer on the second cover sheet to produce an absorbent body comprised of the first cover sheet, the second cover sheet and the absorbent material layer interposed between the first cover sheet and the second cover sheet.

Abstract: A method of manufacturing a multi-layer outer panel for a game ball includes three-dimensionally forming a top layer of an outer panel, as well as one or more backing materials disposed underneath the top layer, into a shape substantially corresponding to the surface of the ball. Multi-layer outer panels are then attached to or interconnected to surround an inflatable bladder, thereby producing a game ball while minimizing overstretching of the outer material or the backing material and improving resistance of the outer panels to delamination.

Abstract: A method produces components from high-temperature-proof fiber reinforced composite ceramics from tapes containing carbon fibers. Heating and simultaneously compacting under the influence of pressure and temperature produces a force-locking connection in the region of the contact zones. The prebody is carbonized. At least one post-compaction of the prebody is followed by a carbonization of the prebody, in which the tapes are separated from the adjoining tapes in the region outside the contact zones by graphite spacers and inserted into a clamping device. The clamping device is made substantially of graphite. As a result, the tapes and the prebody that is formed therefrom are securely fixed during the processing steps. The components can be utilized as workpiece carriers, carriers for optical components, and in the aerospace field.

Abstract: A laser safety enclosure structure has an outer enclosure made of a formable material with a limited ability to withstand exposure to a laser beam and an inner enclosure composed of a laser beam blocking material capable of indefinitely withstanding exposure to a laser beam of a given wavelength and power level so as to prevent such a laser beam incident on the blocking material from escaping the inner enclosure.

Abstract: Method of manufacturing a laminated thermoforming which consists of a thermoformable plastic resin, resin mixtures or a resin matrix as substrate material of the thermoforming and at least one deformable backing material. The pressure and temperature conditions of the thermoforming are adjusted so that the substrate material and backing material are undetachably connected to each other directly by incorporation and/or melting together, and increasing the pressing pressure by additional compressed air support.

Abstract: A laminate structure for making a cushioned component for a vehicle interior, such as a seat cushion or head rest, has a high density foam bonded to an interior surface of a seat cover material. After the laminate structure is formed into a desired shape for the cushioned component, it is inserted into a vacuum mold having a mold surface with a shape corresponding with a desired exterior surface shape of the cushioned component. Liquid foam-forming material is injected into the laminate structure within the mold and allowed to cure to form the cushioned component. The high density foam of the laminate structure preferably has a density of at least 4 lbs/ft3 and an air permeability of 5 to 100 ft3/ft2 minute. This high density foam may be created by felting a polyurethane foam.

Abstract: An installation device for installing a flexible sensor apparatus on a seating surface of a seat cushion includes an installation fixture having a saddle. The saddle includes a first face having a seating portion recess formed therein which generally conforms to the shape of the seating surface of the seat cushion. The first face further has at least one locating recess formed in the seating portion recess. The locating recess generally conforms to the shape of a portion of the flexible sensor apparatus. The saddle further has ports extending from the locating recess to a vacuum source, wherein a vacuum from the vacuum source retains the flexible sensor apparatus in the locating recess.

Abstract: A process of making a nonwoven fabric comprising providing a three-dimensional surface that comprises surface features that are air permeable, depositing fibers or a web comprising fibers onto the surface, and stabilizing the fibers to form a nonwoven fabric is provided.

Abstract: An apparatus for laminating three-dimensional surfaces includes a formed of rigid material that has an upper surface, a lower surface and a first perimeter. Three-dimensional features are formed in the substrate, commencing at the upper surface, and extending downwardly toward the lower surface. A veneer formed of thin, resilient material having a top surface and a bottom surface is prepared and glue suitable for adhering the veneer to the substrate is applied to its bottom surface. The veneer is positioned on the substrate and pressure is applied to the top surface of the veneer to conform the veneer to the substrate. When the glue has dried, the veneer will be adhered to the upper surface of the substrate and will reflect the three-dimensional features of the substrate. The three-dimensional features of the substrate are produced by manual carving of the upper surface, by application of powered rotary cutting and grinding tools, or by computer-controlled contouring machinery.

Abstract: A process for producing a three-dimensional molding made from a layered composite material comprising a thermoplastic polymer backing, an intermediate layer arranged thereupon and a heat-cured layer applied to the intermediate layer comprises bonding the intermediate layer and the heat-cured layer applied thereto to the backing by heat treatment in a molding system and also giving these a three-dimensional shape prior to or during the heat treatment in the molding system

Abstract: An article comprising (a) a curved substrate having a surface energy below about 38 dynes/cm2; (b) flexible retroreflective sheeting; and (c) a crosslinked pressure-sensitive adhesive adhering the sheeting to the curved substrate. The adhesive contains sufficient polar monomer and tackifier, and is sufficiently crosslinked, to (i) have a glass transition temperature less than −15° C., (ii) permit the sheeting to remain firmly bonded to a low density polyethylene barrel without buckling when cooled from 49° C. to −1° C., and (iii) provide an adhesive bond to the barrel that exhibits increased energy absorption when tested for impact resistance at 0° C. according to ASTM D4272. The adhesive can be manufactured by partially polymerizing some of the ingredients in a pouch using UV radiation, dispersing the pouch and its contents in the other ingredients using an extruder, extrusion coating the adhesive and then UV crosslinking the coating.

Abstract: Process for assembly of a flexible panel on an open structure, and installation to make use of this process. According to the invention, a flexible panel (12) is attached to an open structure (10) by pre-assembling these two parts by cold gluing before they are fixed using attachment devices such as rivets. Cold gluing is done using a gluing cap (48) on the inside of which linear and individual inflatable joints (54, 56) are fitted to press the panel (12) into contact with the framework (10) in unperforated parts of the framework. The time necessary for assembly is thus very much reduced, while the quality of part positioning is unaffected.

Abstract: A method of making an interior trim panel for attachment to structure of a vehicle includes the steps of placing a trim insert into a cavity of an apparatus and over a first seal thereof. The method also includes the steps of loading a retainer over the trim insert to sandwich the trim insert between the retainer and the first seal and closing the apparatus. The method further includes the steps of filling the cavity with a plastic material and introducing steam into the apparatus to expand the plastic material to form a substrate and bonding the substrate against the trim insert to form an interior trim panel.

Abstract: Hot-melt webs are located on an outer surface of a pad member and an inner surface of a cover member, individually. The pad member and the cover member are heated to melt the hot-melt webs by means of heaters from the sides opposite the webs, individually. As fibrous hot-melt adhesive elements are cut at every turn and separated to insular pieces, they are distributed like mist drops in the outer surface of the pad member and the inner surface of the cover member. Thereafter, the pad member and the cover member are superposed and pressurized so that they are bonded to each other.

Abstract: An adhesive and material dispenser for dispensing single sheets of material from stacks of sheets of material or from rolls of material and applying an adhesive strip to the sheet. The adhesive strip is applied by contacting the adhesive portion of an adhesive transfer tape to the sheet. The sheet of material with the adhesive strip applied thereto can be used to wrap floral arrangements or flower pots or other articles. The dispenser may be combined with an automatic pot wrapping apparatus so the adhesive application and decorative pot wrapping sequence can be combined into one continuous operation.

Abstract: A trim component (1) includes a substrate (2) and two different cover materials (3, 4), which are not spliced together but are independently adhesively bonded onto the substrate (2) by a hot-melt contact adhesion. The junction (7) is received in a valley (6) of the substrate that is pinched closed using a molding apparatus that includes a horizontally movable pinching stamp (13) which forms a pinching gap (16) relative to a protruding edge (11A) of a fixed mold tool (11). A tucking blade (22) cooperates with a counter-clamping blade (26) to clampingly hold and then press the substrate and junction of the cover sheets into the pinching gap. The tucking blade is then retracted while the pinching stamp pinches closed the pinching gap, to form a tightly closed valley in the substrate with the junction cleanly pinched therein.

Abstract: A dual-laminate honeycomb panel permits the use of two or more different materials to form a single panel. In this manner, a retractable covering for an architectural opening may be formed that has a different appearance depending upon which side of the panel is being viewed. The resultant panel is formed by attaching a plurality of elongated precursor tubular cells, wherein each precursor tubular cell itself comprises two strips of material attached to one another.

Abstract: A bicycle saddle is produced through the steps of providing a fabric/film having a selected perimeter contour and disposing the fabric/film into a mold with the fabric/film perimeter surrounding a mold cavity, the cavity having a bicycle saddle contour. A gelable polymer is disposed into the mold cavity and onto the fabric/film and the fabric/film is conformed to the mold cavity to form a shaped elastomer adhering to the fabric/film in order to permanently contour the fabric/film in the shape of the bicycle saddle contour. A bicycle saddle shell is heated to a temperature sufficient to bond the shell to the shaped elastomer and pressed onto the shaped elastomer to bond the shaped elastomer to the top surface of the shell.

Abstract: A material dispenser for dispensing single sheets of material from stacks of sheets of material or from rolls of material and applying an adhesive strip to the sheet. The adhesive strip is applied by contacting the adhesive portion of an adhesive transfer tape to the sheet. The sheet of material with the adhesive strip applied thereto can be used to wrap floral arrangements or flower pots or other articles. The apparatus may be combined with an automatic pot wrapping apparatus so the adhesive application and decorative pot wrapping sequence can be combined into one continuous operation.

Abstract: A method is provided for application of a layer permanently adhering to the inside of a breast prosthesis formed as a shell-shaped body made from a soft-elastic material, in which a two-component silicone rubber forming the adhesive layer is injected into a mold prior to curing of the body and then cured together with the body. Alternatively, the two-component silicone rubber forming the adhesive layer is first cured in a shell, with the shell then being applied to the body in a mold and then cured again with the body. In a third alternative, the adhesive layer is cured while being joined to a carrier film, with the carrier film then being adhered to the prosthesis sheath which is then filled with addition-vulcanizing two-component silicone rubber and cured in a mold.

Abstract: A panel of a material is transported in operative proximity to an air knife having a nozzle and a curved Coanda surface, such that the panel is folded over the curved Coanda surface as the material is transported in a machine direction. The panel can be folded to a variety of angles and can comprise a refastenable fastening component. Air knives are employed in various methods for folding garment side panels and forming prefastened garments, such as refastenable pants.

Abstract: The method of this invention concerns bonding side-to-side glass or plastic building blocks to obtain decorative and/or functional modular sub-assemblies, walls, panels, floors, windows, skylights, etc., using flexible, light-weight, elongated, adhesive tape strips to adhesively bond together at least portions of complementary block side surfaces to construct multi-tier building block units.

Abstract: A method of depositing a thin membrane so that it conforms to an irregular shaped surface of a scintillator includes the steps of aligning the membrane in a desired position with respect to the irregular surface so that the membrane is in contact with at least some protruding portions of the scintillator, and drawing the membrane down over the irregular surface so that the membrane is conformingly disposed around substantially all protrusions without deforming or bending the needle-like protrusions. The membrane is drawn down by applying a substantially uniform differential pressure across the thin membrane so as to urge the membrane into conformal contact with irregular surface. An imager array fabricated with this process includes a scintillator having an irregular surface and a monolithic reflective layer disposed thereover in conformal contact with the irregular surface.