Heat Settable Impregnant Patents (Class 264/137)
  • Patent number: 6447648
    Abstract: A Conventional blanket material, preferably a woven fabric or scrim, is formed into a loop of the desired dimensions and impregnated and coated with a two-component urethane resin. As the urethane is applied to the woven substrate, short fibers are introduced into the urethane through a nozzle which aligns the fibers to run in the cross-machine direction. The fibers are introduced in sufficient quantities to provide significant structural reinforcement of the urethane in the cross-machine direction. The coated blanket is then ground to a desired constant thickness and an array of parallel grooves running in the machine direction are milled into the urethane coating. The anisotropic fiber reinforcement provides sufficient modulus to the urethane system to prevent the grooves from collapsing under the applied loads of the extended nip press. The reinforcing fibers may be glass, carbon fiber, synthetic polymer or other structural fiber material.
    Type: Grant
    Filed: August 13, 1996
    Date of Patent: September 10, 2002
    Assignees: Metso Paper, Inc., Mitsubishi Heavy Industries, Ltd.
    Inventors: Eugene L. Slagowski, Paul McCarten
  • Publication number: 20020121720
    Abstract: A method of preparing a reinforcing structure for use in manufacture a pultruded part where the reinforcing structure is pulled through a pultrusion die in a continuous longitudinal pull direction. The method includes arranging a plurality of first reinforcing fibers in a transverse direction and attaching a permeable transport web of staple fibers to the first reinforcing fibers such that the portion of the first reinforcing fibers oriented in the direction transverse comprises at least 40% of a volume of materials comprising the reinforcing structure.
    Type: Application
    Filed: December 11, 2001
    Publication date: September 5, 2002
    Applicant: Pella Corporation
    Inventors: Laurence W. Davies, Peter J. Fritz, Kenneth D. Beer
  • Publication number: 20020121712
    Abstract: The invention relates to an apparatus and method for fabricating FRP parts. More specifically, the invention relates to a method for forming FRP parts without the use of forms or molds. According to a preferred embodiment of the present invention, the method for fabricating an FRP part comprises the steps of: programming a readable definition of a part into a machine, wherein the machine moves an extrusion head mounted to the machine in a controlled pattern; and wherein the machine regulates the speed of extrusion from the extrusion head; feeding a fiber reinforcement to the extrusion head of the machine; impregnating the fiber reinforcement with a radiation-initiated resin; extruding the impregnated fiber reinforcement from an orifice in the extrusion head; and exposing the extruded fiber reinforcement to curing radiation.
    Type: Application
    Filed: March 1, 2002
    Publication date: September 5, 2002
    Inventor: Ernest C. Schroeder
  • Publication number: 20020121722
    Abstract: A method of making a pultruded part having a uniform cross-section using a novel reinforcing mat. The method comprises orienting a plurality of longitudinal rovings along a longitudinal axis of a pultrusion die; providing a reinforcing structure comprising a permeable transport web of staple fibers attached to a plurality of first reinforcing fibers oriented so that the portion of the first reinforcing fibers oriented in a direction transverse to the longitudinal axis comprises at least 40% of a volume of materials comprising the reinforcing structure; shaping the reinforcing structure to generally conform with a profile of the pultrusion die; combining a resin matrix with the longitudinal rovings and the reinforcing structure in the pultrusion die so that the longitudinal rovings and the reinforcing structure are substantially surrounded by the resin matrix; at least partially curing the resin matrix in the pultrusion die; and pulling the pultruded part from the pultrusion die.
    Type: Application
    Filed: December 11, 2001
    Publication date: September 5, 2002
    Applicant: Pella Corporation
    Inventors: Laurence W. Davies, Peter J. Fritz, Kenneth D. Beer
  • Patent number: 6408915
    Abstract: An apparatus for monitoring the cure of a resin-impregnated material includes a pultrusion die; a plurality of first electrodes mounted in the pultrusion die; a plurality of insulators surrounding the plurality of first electrodes, respectively, in the pultrusion die; a resin-impregnated preform that includes a second electrode therein, the resin-impregnated preform being inserted into the pultrusion die; a constant contact electrode that contacts the second electrode; and a power supply connected to the constant contact electrode wherein electric current flows from the power supply to the constant contact electrode then to the second electrode then through the resin-impregnated preform to the plurality of first electrodes.
    Type: Grant
    Filed: February 18, 2000
    Date of Patent: June 25, 2002
    Assignee: The United States of America as represented by the Secretary of the Army
    Inventors: William O. Ballata, David Spagnuolo, J. Robert Klinger
  • Patent number: 6395209
    Abstract: The present invention relates to a deposited plastic film comprising: a deposited plastic film comprising: a plastic film; a coating layer which is formed on at least one surface of said plastic film and comprises a cured resin composition obtained by curing a resin composition comprising 6 to 80% by weight of an oxazoline group-containing water-soluble polymer; and a deposit layer which comprises a metal, metal oxide or mixture thereof and is formed on a surface of said coating layer.
    Type: Grant
    Filed: September 24, 1998
    Date of Patent: May 28, 2002
    Assignees: Mitsubishi Chemical Corporation, Mitsubishi Polyester Film Corporation
    Inventors: Shigenobu Yoshida, Yuzou Otani
  • Patent number: 6395210
    Abstract: A method and device for forming composites using a pre-consolidated tubular braid (i.e., a braid removed from the braiding machine on which it was produced prior to use in further processing) including feeding the pre-consolidated tubular braid over a supporting mandrel, impregnating the braid with a resin using a pressurized resin injection chamber with a mandrel adapted to provide adequate impregnation, feeding the resin saturated braid into a pultrusion die with a mandrel for forming and heating and pulling the cured composite from the die for finishing the end product.
    Type: Grant
    Filed: May 12, 1999
    Date of Patent: May 28, 2002
    Assignee: A&P Technology, Inc.
    Inventors: Andrew A. Head, Donald Lambert, John Peter
  • Publication number: 20020045690
    Abstract: The invention relates to polyisocyanurate systems, pultrusion of those systems to produce reinforced polyisocyanurate matrix composites, and to composites produced thereby. The polyisocyanurate systems include a polyol component, an optional chain extender, and an isocyanate. The polyisocyanurate systems have extended initiation times of about 5 minutes to about 30 minutes at room temperature, and can be snap cured.
    Type: Application
    Filed: May 16, 2001
    Publication date: April 18, 2002
    Inventors: Evan H. Cheolas, Berend Eling, Ravi R. Joshi
  • Publication number: 20020031971
    Abstract: A crosslinkable cellulosic fibrous product that includes cellulosic fibers and a crosslinking agent is disclosed. The crosslinkable cellulosic fibrous product can be formed as a web or sheet that has structural integrity and sheet strength sufficient to permit the fibrous web to be rolled, transported, and used in rolled form in subsequent processes. The crosslinkable fibrous product can be converted into a crosslinked fibrous product by subjecting the product to conditions sufficient to effect intrafiber crosslinking. Alternatively, the web can be fiberized and the resulting individual crosslinkable fibers combined with other fibers and/or other materials to provide a fibrous web containing crosslinkable cellulosic fibers. Subjecting such a web to crosslinking conditions provides a fibrous web that includes, in addition to other fibers or materials, crosslinked cellulosic fibers.
    Type: Application
    Filed: August 30, 2001
    Publication date: March 14, 2002
    Applicant: Weyerhaeuser Company
    Inventors: John A. Westland, Colin Elston
  • Patent number: 6325958
    Abstract: Cores for manufacture of molded products are fabricated from ceramic microspheres in combination with 5-20% polymer binder in water solution, the binder comprising poly(2-ethyl-2-oxazoline) and polyvinylpyrrolidone.
    Type: Grant
    Filed: May 9, 2000
    Date of Patent: December 4, 2001
    Assignee: Advanced Ceramics Research, Inc.
    Inventors: John Lang Lombardi, Gregory John Artz
  • Patent number: 6319443
    Abstract: A method of manufacturing fiber reinforced plastics comprising immersing fibers into an immersing tank containing resin, moving the fibers through the immersing tank along a direction in which the fibers are aligned at a speed that is substantially equal to a rate of capillary infiltration of the resin into the fibers, and drawing the fibers into a die to cure the resin.
    Type: Grant
    Filed: March 16, 1999
    Date of Patent: November 20, 2001
    Assignee: NGK Insulators, Ltd.
    Inventor: Shigeo Ishino
  • Patent number: 6306320
    Abstract: A method of increasing the amount of entrained vapor in fiber-reinforced resin composite materials, and in particular filament wound composites, wherein a particularly effective chemical foaming or blowing agent is incorporated into the resin matrix composition used to form the composites. The foaming agent creates vapor-filled voids throughout the resin matrix of the composite as it cures. The superior composites containing these vapor-filled voids demonstrate high burst strength retention and excellent resistance to cyclic fatigue. The invention also relates to composite materials and articles thereof.
    Type: Grant
    Filed: July 29, 1999
    Date of Patent: October 23, 2001
    Assignee: Owens Corning Fiberglas Technology, Inc.
    Inventors: Martin Charles Flautt, Byron Jeffrey Hulls, David George Miller
  • Patent number: 6299810
    Abstract: A system and method of forming a carbon fiber composite material in which a series of carbon fibers are woven together and treated with a resin to form a sample or weave. The carbon fiber sample is then vacuumed, compressed and is cured to form a solid plank or board that is then cut, sanded and polished to form a finished product.
    Type: Grant
    Filed: May 18, 1999
    Date of Patent: October 9, 2001
    Assignee: Michael RiCharde, LLC
    Inventor: Richard E. Blackinton, Jr.
  • Patent number: 6292990
    Abstract: The present invention realizes spreading a sheet on a frame member by a simple structure and a simple process, and prevents uneven tension charged against the sheet. In the sheet spreading method of the invention, a core member for a backrest of a chair which is heated to around 200° C. in a furnace is put into a flow dipping tank filled with powder resin. As a result, a resin coating is formed on the surface of the pipe constituting the core member. Also, a mesh is placed on a metal mold and clamped. Since a recess corresponding to the shape of the core member is formed in the top side of the metal mold, the mesh is spread on the core member with a tension charged against when the core member having the above-mentioned coating is pressed into the recess.
    Type: Grant
    Filed: December 9, 1999
    Date of Patent: September 25, 2001
    Assignee: Aichi Co., Ltd.
    Inventors: Toru Iseki, Takehiko Kawashima
  • Publication number: 20010021427
    Abstract: A wind tunnel blade (30) connected to a base (32) and held in position by a two-piece cuff (34). The wind tunnel blade (30) is formed in a resin transfer molding process in which central, fore, and aft foam core sections (70, 72, 74) are placed together to form the wind tunnel blade (30). Radius fillers (120) are used to fill the gaps between the outer edge of the foam core sections. The radius fillers (120) used in the wind tunnel blade (30) are formed by a braided sleeve (122) surrounding a number of unidirectional tows (124). A tip (68) is formed separately from the rest of the wind tunnel blade (30) and is glued to the top thereof. Stacked layers of braided fibers (100) are used to reinforce the central core section (70).
    Type: Application
    Filed: April 4, 2001
    Publication date: September 13, 2001
    Applicant: The Boeing Company
    Inventors: Thomas R. Cundiff, Henry H. Bennett, Brad G. Lund, Robert S. Renz, Donald E. Wright
  • Patent number: 6287498
    Abstract: A method of manufacturing flexible belts from fibers. Fibers that form the flexible belt are soaked with a liquid elastomer. The liquid elastomer soaked fibers are formed into the shape of a belt, beneficially by wrapping the fibers around a mandrel. The belt-shaped and soaked fibers are then cured. Multiple layer flexible belts can be formed by soaking fibers with a first liquid elastomer, wrapping those fibers around a mandrel, and then curing the mandrel to form a belt layer. Then, fibers are soaked with a second liquid elastomers. Those soaked fibers are then wrapped around the mandrel/belt layer. The fibers soaked with the second elastomer are then cured, forming a belt having two layers. The formed belt is then removed from the mandrel. The fibers and liquid elastomer(s) are beneficially chosen to introduce desirable belt properties.
    Type: Grant
    Filed: December 15, 1999
    Date of Patent: September 11, 2001
    Assignee: Xerox Corporation
    Inventors: Edward L. Schlueter, Jr., William E. Bond
  • Patent number: 6277238
    Abstract: The method for the manufacture of sections of fiber-plastic compound materials is carried out by means of at least one draw nozzle (10). In this nozzle, fibers (41) which are impregnated with flowable plastic (42) are formed under pressure to a product (41) with a predetermined cross-section and consolidated with the withdrawal of heat. The cross-sectional surface of the draw nozzle is periodically increased and decreased in time in its entire shape imparting region, with a value for the frequency of the oscillating cross-sectional surface being chosen less that 1 kHz, preferably less than 100 Hz.
    Type: Grant
    Filed: August 3, 1999
    Date of Patent: August 21, 2001
    Assignee: Sulzer Innotec AG
    Inventors: Albert Maria Vodermayer, Jens Kärger, Hans Erlach
  • Publication number: 20010013669
    Abstract: A wind tunnel blade (30) connected to a base (32) and held in position by a two-piece cuff (34). The wind tunnel blade (30) is formed in a resin transfer molding process in which central, fore, and aft foam core sections (70, 72, 74) are placed together to form the wind tunnel blade (30). Radius fillers (120) are used to fill the gaps between the outer edge of the foam core sections. The radius fillers (120) used in the wind tunnel blade (30) are formed by a braided sleeve (122) surrounding a number of unidirectional tows (124). A tip (68) is formed separately from the rest of the wind tunnel blade (30) and is glued to the top thereof. Stacked layers of braided fibers (100) are used to reinforce the central core section (70).
    Type: Application
    Filed: April 4, 2001
    Publication date: August 16, 2001
    Applicant: The Boeing Company
    Inventors: Thomas R. Cundiff, Henry H. Bennett, Brad G. Lund, Robert S. Renz, Donald E. Wright
  • Patent number: 6270706
    Abstract: A method of forming or treating an article or preform (10) and an article or preform made according to the method are provided. The method includes the step of providing around at least part of the article or preform (10) a generally tubular element (14) whose effective cross-section tends to reduce on extension, and applying an extension load to the tubular element (14) thereby to apply a compression load to the exterior of the article or preform to aid consolidation thereof.
    Type: Grant
    Filed: April 24, 1998
    Date of Patent: August 7, 2001
    Assignee: BAE Systems PLC
    Inventor: James Ball
  • Patent number: 6254810
    Abstract: One may obtain an excellent protective coating for a fabric made of heat-resistant fibers, in particular a fabric made of glass fibers like those used for the manufacture of filters in the metallurgical industry, when use is made, as a starting material, of a composition comprising an organic part made of sugar and a mineral part comprising colloidal silica and wollastonite. This composition allows thermoforming of the fabric and gives to the same a very strong protection and a rigidity. This is particularly interesting when the fabric is used for making a filter like those used during the casting of a liquid metal, especially liquid aluminum.
    Type: Grant
    Filed: February 9, 1998
    Date of Patent: July 3, 2001
    Assignee: Cerminco Inc.
    Inventors: Pierre Delvaux, Luc Desrosiers, Marcel Gouin, Michel Rouleau
  • Patent number: 6221293
    Abstract: A method for producing a compound from a plastics material with fixed fiber inlay uses a heated screw-type extruder (1) in which filaments (2) are drawn by means of automatic drawing-in, are cut up and mixed there and are subsequently removed as a finished fiber compound. To achieve a high content of long fibers in the finished fiber compound, before entering the extruder (1) the filaments (2) are impregnated with the plastics material in an impregnation tool (3).
    Type: Grant
    Filed: December 9, 1998
    Date of Patent: April 24, 2001
    Assignee: Menxolit-Fibron GmbH
    Inventors: Richard Brussel, Rudolf Kuhfusz
  • Patent number: 6159398
    Abstract: An improved method of making laminated optical components through the use of a master and several submasters is disclosed. A glass/photoresist master is made by recording optical surface features in the photoresist with coherent or incoherent light. The master is processed to reveal the surface features. A frame is fastened to the edges of the photoresist/glass master with edges rising slightly above the top surface of the master. Silicone rubber is poured into the frame over the photoresist layer and allowed to cure. The silicone rubber submaster is then separated from the photoresist/glass master. Use of silicon rubber permits separation of the submaster without damaging the master. Additionally, silicone rubber is less prone to shrinkage than prior art submasters thus permitting more accurate copying of the surface features of the photoresist/glass master. Subsequent epoxy replicas may then be made from the silicone rubber submaster.
    Type: Grant
    Filed: March 31, 1998
    Date of Patent: December 12, 2000
    Assignee: Physical Optics Corporation
    Inventors: Gajendra D. Savant, Abbas Hosseini
  • Patent number: 6149971
    Abstract: Fireproof panels, and methods for their construction are provided. The fireproof panels comprise at least one sheet including a layer of glass fibres impregnated with at least one fireproof resin free from solvent. The method for the construction includes the successive steps of distributing a fireproof resin in the form of a powder free from solvents on a layer of glass fibres, subjecting the latter to a first compression and heating step to soften the resin and, to a second compression and heating step to cross-link the resin and form the said panel. The panels find particular use in the production of partitions and furnishings.
    Type: Grant
    Filed: December 9, 1996
    Date of Patent: November 21, 2000
    Assignee: Eurocompositi S.r.l.
    Inventor: Adriano Lusardi
  • Patent number: 6132658
    Abstract: A wood grain finish to a pultruded part is obtained by applying to a surface of the part before entering the die a strip carrying male projections shaped in differential depths and spacing across the width of the part to form a simulated wood grain pattern. The strip is then removed after the part is set leaving recesses in the outside surface which provide a simulated wood grain finish which can be differentially stained.
    Type: Grant
    Filed: March 3, 1998
    Date of Patent: October 17, 2000
    Inventor: Lawrence W. Davies
  • Patent number: 6132651
    Abstract: A magnetic recording medium having a substrate disc with microscopic bumps formed by focusing a laser beam, wherein spacings D between adjacent bumps in the circumferential direction of the disc are varied so that formula (1) is satisfied:1.ltoreq.[(D.sub.max -D.sub.min)/D.sub.avg ].times.100(%).ltoreq.200(1)wherein D.sub.max, D.sub.min and D.sub.avg are the maximum, minimum and average spacings, respectively, as determined by a method wherein 2.5% of the total number of spacings D, having the largest dimensions, and 2.5% of the total number of spacings D, having the smallest dimensions, are excluded; and D.sub.max, D.sub.min and D.sub.avg are measured on the remaining 95% of the total number of spacings D. The variation of bump spacings is attained, for example, by (i) modulating the pulse repetition frequency F of laser beam so that the ratio of "(F.sub.max -F.sub.min)/F.sub.avg " is maintained within the range of 0.01 to 100, wherein F.sub.max, F.sub.min and F.sub.
    Type: Grant
    Filed: June 10, 1999
    Date of Patent: October 17, 2000
    Assignee: Showa Denko K.K.
    Inventors: Hiroshi Ohsawa, Hiroyuki Watanabe
  • Patent number: 6118913
    Abstract: A system for staking a haptic to an optic to form an intraocular lens using a laser beam operating near the infrared range with a coaxial aiming laser beam operating in the visible range. A portion of the haptic is inserted into the optic through a radial bore and is exposed through an axial bore spanning from the optic upper surface to the radial bore. The coaxial laser beams are collimated and then focused using a microscope objective through the axial bores, onto the exposed haptic. Aiming of the coaxial beams onto the optic and haptic is aided by the use of a magnifying CCD camera positioned with its optical axis at a 45.degree. angle to the optic horizontal plane. The coaxial lasers, which are typically focused to a minor diameter which is greater than or equal to the inner diameter of the axial bore, make contact with the exposed haptic. Consequently, the haptic is melted and is then allowed to cool, coalescing into a bead staking the haptic to the optic.
    Type: Grant
    Filed: March 20, 1998
    Date of Patent: September 12, 2000
    Assignee: Ciba Vision Corporation
    Inventors: John J. O'Connor, Lawrence Y. Wissman
  • Patent number: 6113722
    Abstract: The invention comprises devices composed of at least one microscopic hollow tube having a wall of single or multiple layers with a thickness of at st one nanometer and a diameter of at least 5 nanometers. The walls of the tubes can be formed from a wide variety of materials, some of the preferred materials include metals, polymers, carbon, ceramics, glasses. If the space between the tubes is filled, the tubes become channels in a monolithic or composite body. The channels can have a random or ordered orientation. The interior of the tube walls can be coated with a desired material such as a catalyst and also may have depressions or elevations therein that were imparted to the fibers upon which the tubes are formed. The wall layers may be porous for the purpose of removing the fiber therethrough. Microtubes and microtube devices may be interfaced with the macroscopic world in a number of ways.
    Type: Grant
    Filed: September 12, 1997
    Date of Patent: September 5, 2000
    Assignee: The United States of America as represented by the Secretary of Air Force
    Inventors: Wesley P. Hoffman, Phillip G. Wapner
  • Patent number: 6099786
    Abstract: A method of making accurate alignment layers in a liquid crystal display (LCD) cell is provided so that the LCD seal band can be placed as close to the pixel as possible. This method is implemented by ablating the apolyimide film on the glass substrates of the LCD cell to remove the alignment film where the sealing material is to be dispersed later. Thus, the sealing band can butt against the liquid crystal mixture without any clearance. In so doing, the display area is increased, and the reliability of the seal is improved.
    Type: Grant
    Filed: February 23, 1996
    Date of Patent: August 8, 2000
    Assignee: Prime View International Co.
    Inventors: Dyi-Chung Hu, Sheng-Heisn Lin, Tai-Kang Wu, Sywe N. Lee
  • Patent number: 6077349
    Abstract: When applying a coating film by a spin coating method on a disc-shaped recording medium, the film thickness difference between the inner rim and the outer rim of the disc has to be suppressed. To this end, a coating liquid is supplied to a center portion of the disc-shaped recording medium and a rotary disc, as a center shaft of a rotary disc is inserted into a recess formed in a turntable on which the disc-shaped recording medium is set and the disc-shaped recording medium and a rotary disc are run in rotation. The coating liquid is spread under the centrifugal force caused by rotation for forming a coating film on the disc-shaped recording medium.
    Type: Grant
    Filed: August 19, 1998
    Date of Patent: June 20, 2000
    Assignee: Sony Corporation
    Inventor: Minoru Kikuchi
  • Patent number: 6074595
    Abstract: Methods for making tubular pressure vessels from polymer-impregnated fibrous material utilize cylindrical mandrels that are helically wound while rotating about a horizontal axis. After end closure fittings are installed on the mandrel, a barrier layer having a thickness of about 0.015 in is created by helically winding a strip of nonwoven polyester fiber material which is impregnated and coated with a mixture of two resin systems, one which is promptly cured by UV radiation while the other remains uncured. The resultant barrier layer is stable and drip-free and is inspected so minor defects can be remedied. A time lag of several hours before winding the major portion of the sidewall of the barrier layer subassembly is completely acceptable if an epoxy resin plus acid anhydride curing agent system is used having an extended pot-life of 12 to 15 hours.
    Type: Grant
    Filed: October 16, 1998
    Date of Patent: June 13, 2000
    Assignee: Codeline Corporation
    Inventors: Douglas Eisberg, Terry Gilbertson, Christian Gargiulo
  • Patent number: 6065197
    Abstract: The present invention realizes spreading a sheet on a frame member by a simple structure and a simple process, and prevents uneven tension charged against the sheet. In the sheet spreading method of the invention, a core member for a backrest of a chair which is heated to around 200.degree. C. in a furnace is put into a flow dipping tank filled with powder resin. As a result, a resin coating is formed on the surface of the pipe constituting the core member. Also, a mesh is placed on a metal mold and clamped. Since a recess corresponding to the shape of the core member is formed in the top side of the metal mold, the mesh is spread on the core member with a tension charged against when the core member having the above-mentioned coating is pressed into the recess.
    Type: Grant
    Filed: March 1, 1999
    Date of Patent: May 23, 2000
    Assignees: Aichi Co., Ltd., Asahi Gomu Kako K.K.
    Inventors: Toru Iseki, Takehiko Kawashima
  • Patent number: 6048488
    Abstract: Multiple resin transfer molding is the simultaneous injection of differing esins in fiber preforms with or without a separation layer. The flow of the resins is controlled by varying the permeabilities of the preforms and the separation layer. The method produces multifunctional hybrid composites made of multilayered preforms and multiple resins. A fundamental advantage of the invention is the simplification of the manufacturing process.
    Type: Grant
    Filed: October 23, 1997
    Date of Patent: April 11, 2000
    Assignee: The United States of America as represented by the Secretary of the Army
    Inventors: Bruce K. Fink, John Gillespie, Emanuele Gillio, Karl Bernetich
  • Patent number: 6039899
    Abstract: An automated method and apparatus is provided to mold and cure soft contact lenses. A molding station injection molds first and second mold parts for the production of the lenses and these mold parts are transferred to an inert gas or low oxygen environment wherein a series of automated stations receive the mold parts, deposit a polymerizable hydrogel within the first mold part, assemble and clamp the first and second mold parts together, apply radiant energy for polymerizing the hydrogel and subsequently separate the mold parts.
    Type: Grant
    Filed: January 9, 1998
    Date of Patent: March 21, 2000
    Assignee: Johnson & Johnson Vision Products, Inc.
    Inventors: Wallace Anthony Martin, Jonathan Patrick Adams, Finn Thrige Andersen, Stephen Robert Beaton, Svend Christensen, Allan G. Jensen, Ture Kindt-Larsen, Victor Lust, Craig William Walker, Daniel Tsu-Fang Wang
  • Patent number: 6033510
    Abstract: A method for fabricating composite structures at a low-cost, moderate-to-high production rate. A first embodiment of the method includes employing a continuous press forming fabrication process. A second embodiment of the method includes employing a pultrusion process for obtaining composite structures. The methods include coating yarns with matrix material, weaving the yarn into fabric to produce a continuous fabric supply and feeding multiple layers of net-shaped fabrics having optimally oriented fibers into a debulking tool to form an undebulked preform. The continuous press forming fabrication process includes partially debulking the preform, cutting the partially debulked preform and debulking the partially debulked preform to form a netshape. An electron-beam or similar technique then cures the structure. The pultrusion fabric process includes feeding the undebulked preform into a heated die and gradually debulking the undebulked preform.
    Type: Grant
    Filed: September 23, 1997
    Date of Patent: March 7, 2000
    Assignee: The United States of America as represented by the United States National Aeronautics and Space Administration
    Inventor: Gary L. Farley
  • Patent number: 6033511
    Abstract: A method for fabricating composite structures at a low-cost, moderate-to-high production rate. A first embodiment of the method includes employing a continuous press forming fabrication process. A second embodiment of the method includes employing a pultrusion process for obtaining composite structures. The methods include coating yarns with matrix material, weaving the yarn into fabric to produce a continuous fabric supply and feeding multiple layers of net-shaped fabrics having optimally oriented fibers into a debulking tool to form an undebulked preform. The continuous press forming fabrication process includes partially debulking the preform, cutting the partially debulked preform and debulking the partially debulked preform to form a net-shape. An electron-beam or similar technique then cures the structure. The pultrusion fabric process includes feeding the undebulked preform into a heated die and gradually debulking the undebulked preform.
    Type: Grant
    Filed: September 23, 1997
    Date of Patent: March 7, 2000
    Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space Administration
    Inventor: Gary L. Farley
  • Patent number: 6030556
    Abstract: Optical disc stampers, methods of manufacturing the optical disc stampers, systems for manufacturing the optical disc stampers, and methods of replicating optical discs using the stampers are disclosed. The optical disc stamper is formed directly on a substrate that supports a patterning material including at least one layer of a first material and at least one layer of a second material. The first and second materials can include a metal and semiconductor. The patterning material is exposed to energy in selected areas. Unexposed areas of the patterning material are then removed, resulting in an optical disc stamper. The first and second materials can form an amorphous alloy in the exposed selected areas that remains after removal of the unexposed patterning material. The optical disc stamper can be used in the replication of optical data storage discs. Also disclosed arc systems for practicing the methods to produce optical data storage disc stampers.
    Type: Grant
    Filed: July 8, 1997
    Date of Patent: February 29, 2000
    Assignee: Imation Corp.
    Inventors: James M. DePuydt, Walter R. Eppler, Michael B. Hintz
  • Patent number: 6008467
    Abstract: In a method for forming a hole for fitting an optical fiber only at a core portion without having to precisely match or accord the focus of a laser beam with the end surface of an optical waveguide, when a laser beam is irradiated onto the end surface of the optical waveguide, the focus of the laser beam is turned away from the end surface of the optical waveguide and a region of the irradiation includes the core and the periphery thereof. Thereafter, the energy of the laser beam is increased step by step, and a few pulses thereof are radiated with the intensity fixed when ablation occurs at the core portion, so that the hole is formed only at the core portion.
    Type: Grant
    Filed: October 3, 1997
    Date of Patent: December 28, 1999
    Assignee: Nippon Sheet Glass Co., Ltd.
    Inventors: Keiji Tsunetomo, Tadashi Koyama
  • Patent number: 6004487
    Abstract: Method and apparatus for a disk texturing operation in which laser pulses are successively bombarded against a delimited surface area on the face of a rotating disk, from an optical laser pulse irradiating means which is put in movement in a radial direction relative to the disk to provide a textured zone of a predetermined width on the disk. A pulsed laser beam from a laser light source is adjusted to an optimum power level for an aimed bump diameter. The laser beam is then transformed into an annular beam of a collimated light flux having specified inner and outer diameters, and the resulting laser pulses are successively bombarded on the texturing zone through an objective optical system condensing said laser pulses into a specified spot diameter thereby to form minute bumps of predetermined shape and diameter uniformly on the surface of the disk.
    Type: Grant
    Filed: July 7, 1998
    Date of Patent: December 21, 1999
    Assignee: Hitachi Electronics Engineering Co., Ltd.
    Inventors: Kenya Wada, Hisayoshi Ichikawa, Kazuto Kinoshita, Shinji Sugizaki
  • Patent number: 6001300
    Abstract: A process for manufacturing simple or complex reinforcement preforms for use in resin transfer molding (RTM), structural reaction injection molding (SRIM) or similar molding processes includes applying a thermosetting binder, which is sensitive to selected ultraviolet or microwave radiation, to planar woven or non-woven reinforcing materials, the binder-bearing reinforcing material being placed into a three-dimensional mold and pressed into a desired shape, cured in the mold by applying a corresponding selected ultraviolet or microwave energy thereto to cure and rigidize the binder and hold reinforcement material in the three-dimensional shape resulting in a rigid three-dimensional preform to be used in subsequent molding operations. Structural reinforcements, sub-assemblies and the like may be applied to the preform to enhance the final properties of the final composite structure.
    Type: Grant
    Filed: December 6, 1989
    Date of Patent: December 14, 1999
    Assignee: C.A. Lawton Company
    Inventor: Daniel T. Buckley
  • Patent number: 5989376
    Abstract: Disclosed are profiles of fiber-reinforced polymeric plastic and a pultrusion apparatus and method for the manufacture thereof. The apparatus is preferably vertically disposed. As one or more fibers is fed into the apparatus, each fiber is spread and wetted with monomer resin in a bundle spreader, formed in a die, and then subjected in a curing chamber to a source of radiation which initiates polymerization of the monomer, resulting in a fiber-reinforced polymeric plastic exiting from the pultrusion apparatus. Suitably, the radiation is ultraviolet, the monomer resin is methacrylate resin, and the fiber is quartz. The resultant profile is long and thin like a structural steel wire, but typically will have only 1/4 the weight thereof while having a strength comparable thereto. Thus, the profile is useful as an orthodontic wire as a replacement instead of structural steel wires used as orthodontic wires.
    Type: Grant
    Filed: November 20, 1997
    Date of Patent: November 23, 1999
    Assignee: The University of North Carolina at Chapel Hill
    Inventors: Robert P. Kusy, Kenneth C. Kennedy, II
  • Patent number: 5976697
    Abstract: The invention relates to a process for manufacturing an article of a high-density carbon. To produce an un-fired compact, binderless, self-sintering, fine-grained carbon powder, particularly carbon mesophases, with a powder density of more than 1 g/cm.sup.3, particularly more than 1.4 m/cm.sup.3, and an average grain size of between 5 and 20 .mu.m, is precompacted at a low pressure and is pressed in a mold to at a pressure of between 50 and 150 MPa, particularly at approximately 100 MPa. After pressing, the contact pressure is slowly lowered. Then, the un-fired compact is carbonized in a temperature gradient of maximally 20 K/min. The temperature is held constant at a holding temperature of between 500 and 700.degree. C. for a defined holding time and is subsequently raised to a maximal temperature of between 800 and 1,200.degree. C., particularly approximately 1,000.degree. C. Finally, the carbonized compact is graphitized at an end temperature of between 2,500-3,000.degree. C.
    Type: Grant
    Filed: July 18, 1997
    Date of Patent: November 2, 1999
    Assignee: DaimlerChrysler AG
    Inventors: Klaus-Peter Brehler, Jens Schmidt, Michael Scheydecker
  • Patent number: 5972264
    Abstract: A method for fabricating fiber-reinforced composite structures, including centrifuge rotors, by resin transfer molding (RTM) is disclosed. The method involves loading reinforcing fibers into a mold and then injecting resin into the mold to coat the fibers to form the composite structure. Two types of reinforcing fibers are used--fabric preforms at the surfaces of the structure and chopped fibers at the interior of the structure. Also disclosed is a fiber-reinforced composite structure comprising a skin layer of reinforcing fabric, chopped fibers distributed throughout the interior of the structure, and epoxy resin that binds the fabric and chopped fibers together into a fiber-reinforced composite structure. The resin transfer molding method is especially useful for fabricating composite centrifuge rotors.
    Type: Grant
    Filed: June 6, 1997
    Date of Patent: October 26, 1999
    Assignee: Composite Rotor, Inc.
    Inventors: Mohammad Ghassem Malekmadani, Charles Biddle, Hung Nguyen, Reza Sheikhrezai
  • Patent number: 5968441
    Abstract: A laser processing method for ablating a transparent material is disclosed. A laser beam absorption layer is formed in a desired ablation portion beforehand by the implantation of an impurity or the increase of a defect density. The absorption layer obviates damage ascribable to thermal strain and, when use is made of a VUV (Vacuum Ultra Violet) beam, damage to portions other than an irradiated portion. This allows a simple apparatus to implement the ablation of a transparent film.
    Type: Grant
    Filed: October 16, 1998
    Date of Patent: October 19, 1999
    Assignee: Nec Corporation
    Inventor: Yuko Seki
  • Patent number: 5955387
    Abstract: A ceramic composite is provided comprising ceramic fibers, glass microballoons and/or diatoms, bound together with a ceramic reinforcing cloth with a sol-gel ceramic binder. The composite is particularly useful as a high strength, high temperature insulation material.
    Type: Grant
    Filed: June 23, 1997
    Date of Patent: September 21, 1999
    Assignee: The Boeing Company
    Inventor: Darryl F. Garrigus
  • Patent number: 5954904
    Abstract: A head assembly for a pultrusion process for pultruding pultrudable material is provided. The head assembly includes a floating adjustable assembly carrying a pultrusion die. The die has a center line disposed proximate the center line of the process and an entrance, and an exit. The material passing from the entrance to the exit of the die in forming an acceptable finished shape is maintained when formed with the center line of the exit of the die always remaining stationary and disposed proximate the center line of the process.
    Type: Grant
    Filed: February 7, 1997
    Date of Patent: September 21, 1999
    Assignee: Stanley Rokicki
    Inventor: Stanley Rokicki
  • Patent number: 5952435
    Abstract: A composite material for a lateral rigid member of a track belt for use in a snowmobile. A glycidylamine epoxy resin that is a polyfunctional epoxy thermosetting resin and has a molecular weight of about 250 to 1000 is included in an amount of 100 parts by weight. A 2-functional epoxy resin having a molecular weight of about 100 to 600 is included in an amount of 12 to 14.5 parts by weight. An aromatic polycarbonate thermoplastic resin having a molecular weight of about 12000 to 80000, a glass transition point of 130.degree. C. or more, a melting point of 220.degree. C. to 240.degree. C. is included in an amount of 5 to 45 parts by weight. An acid anhydride curing agent is included in an amount of 90 to 130 parts by weight. The composite material also includes reinforcing fiber.
    Type: Grant
    Filed: August 26, 1996
    Date of Patent: September 14, 1999
    Assignee: The Yokohama Rubber Co., Ltd.
    Inventors: Fumio Chiba, Yuichi Tanaka
  • Patent number: 5951731
    Abstract: For forming bores for insertion of optical fibers, etc., on one side surface of a micro lens with high accuracy and easy work, a laser processing method that includes the steps of: irradiating a laser beam onto the one side surface of the micro lens; then focusing the laser beam in a layer having superiority in absorbency with respect to the laser beam; and forming the bores because the laser beam exceeds the threshold value of causing fusion, evaporation or ablation in the superior laser beam absorption layer.
    Type: Grant
    Filed: October 3, 1997
    Date of Patent: September 14, 1999
    Assignee: Nippon Sheet Glass Co., Ltd.
    Inventors: Keiji Tsunetomo, Tadashi Koyama
  • Patent number: 5942165
    Abstract: A method of making irregular shaped playing discs to achieve proper balance for playing involves the use of a grid (7) divided into quadrants (1, 2, 3, 4) having squares of a predetermined size. A template (8) is placed on the grid (7) into which a desired artwork (9) is fitted. The artwork may include face of a recording star, holiday character or other desired item. The artwork (9) must be placed within the template (8) so that an equal number of squares is taken from each quadrant (1, 2, 3, 4) of the grid (7) within the template (8). Once the shape of the artwork is determined, the recording medium, whether it be audio, visual or a combination of both, is applied. The visual appearance of the artwork (9) may then be silk screened or otherwise applied to the disc. Once the above method is accomplished, the disc can be used as a master for making a mold to premold other discs or each disc may be cut around the perimeter of the artwork to result in discs in the shape of the artwork.
    Type: Grant
    Filed: October 20, 1997
    Date of Patent: August 24, 1999
    Assignee: Soundshape, Inc.
    Inventor: Michael A. Sabatini
  • Patent number: 5942070
    Abstract: A method for fabricating a composite pressure vessel comprising layering up of an uncured carbon fiber fabric/resin prepreg on a mold. Thereupon an uncured insulating rubber is layered up and combined with the uncured carbon fiber fabric/resin prepreg by autoclaving. This method produces an insulator for a composite pressure vessel which insulator is an aspect of the present invention.
    Type: Grant
    Filed: August 30, 1996
    Date of Patent: August 24, 1999
    Assignee: Agency For Defense Development
    Inventors: Byeong-Yeol Park, Sang-Ki Chung, Bal Jung
  • Patent number: 5935492
    Abstract: Methods and apparatus which are utilized for the production of ophthalmic lenses, and more particularly, a method for the removal or demolding of molded ophthalmic contact lenses from the individual molds in which they are produced. The apparatus implements the demolding of such ophthalmic lenses, the latter of which may consist of suitable hydrogel contact lenses or other types of high-precision ophthalmic lenses; for example, such as intraocular contact lenses. Mechanical prying apart of such mating mold half portions, and to facilitate this procedure at a reduced application of force, while concurrently potentially preventing or at least appreciably ameliorating the extent of any possible sticking together of the mold half portions is effected in that mechanical leverage applied to the upper mold half portion, in addition to the application of the heating action thereto.
    Type: Grant
    Filed: November 26, 1997
    Date of Patent: August 10, 1999
    Assignee: Johnson & Johnson Vision Products, Inc.
    Inventors: Wallace Anthony Martin, Ture Kindt-Larsen, Craig William Walker