Abstract: Uncured thermoset composite reactants containing ultraviolet curable reagents may be effectively cured by pultrusion using a unique molding die which uniformly irradiates the uncured composites contained within the die. The die includes strategically positioned passageways communicating through the chamber walls of the die to the die chamber. The passageways are equipped with fiber optic cables connected to an ultraviolet generator at one cable end and ultraviolet discharging end for discharging ultraviolet radiation within the die chamber at an opposite cable end. Ultraviolet light conducted to the die chamber by the fiber optic cables uniformly initiates and catalyzes the uncured reactants to produce a fully cured thermoset composite. Uncured composite reactants may be continuously fed to the die as the cured composites are continuously withdrawn from the die.

Abstract: Disclosed is a process of forming a prepreg material having substantially no voids. According to the process of the invention, the reinforcing material is heated to a temperature above the temperature of the impregnating resin. The prepreg formed has substantially no voids and does not require lengthy consolidation when formed into useful articles.

Abstract: A method for manufacturing a shaped panel from a continuous length of an expanded mat. The method includes transporting an expanded mat on a conveyor. The conveyor includes side chains and a plurality of spaced apart slats, which extend transversely between the side chains, on which the expanded mat is supported. The side chains and the plurality of slats define a plurality of openings in the conveyor. A length of the expanded mat is confined and shaped between a male mold and a female mold by moving the male mold and the female mold into mating relationship through one of the plurality of openings in the conveyor.

Abstract: In a guide wire is for a catheter, a core wire prepared by twisting a plurality of thin threads in which a leading end of the core wire is diametrically reduced to be a thinnest tip. A resin layer is coated on an outer surface of the core wire. The thinnest tip is treated by tightly uniting together a twisted ends of the thinnest threads.

Abstract: An apparatus for manufacturing vehicle frame components using composite fiber pultrusion techniques includes one or more sources of a fibrous material. A bath or similar structure is provided for applying a resin material to the fibrous materials from the sources. Following the application of the resin, the fibrous materials are then pulled through a die. The die is formed having an opening therethrough which corresponds in shape to the desired cross sectional shape of the vehicle frame component to be manufactured. As the fibrous materials are pulled through the die, they conform to the shape of the opening formed therethrough. Because of the resin applied thereto, the fibrous materials adhere to one another to form a pultrusion which retains the shape of the opening formed through the die. The formed pultrusion is then pulled through a curing oven which heats the resin to a predetermined curing temperature, causing it to harden a rigid condition.

Abstract: A method for making a corrugated fiber reinforced preform for a corrugated channel is disclosed which involves the sequential application of fiber plies to a shaping tool, each of the plies individually formed to the contours of the shaping tool, using a corrugating tools, restraining means used to maintain the plies in conformance with the tool. The plies are then subjected to debulking and heated to stabilize the fiber plies in their shaped condition, with additional plies applied thereover using the same steps of application, forming, restraining and stabilizing to produce a thick debulked fiber preform which avoids wrinkling of the fibers at the radius between the web and side portions of the corrugated channel.

Abstract: An apparatus for exposing an optical master disk includes an exposure section, an exposure control section, a guide groove exposure voltage supplier and a modulator. The exposure section is for exposing a guide groove and pre-pits by different laser beams, and the exposure control section is for controlling an exposure voltage of the laser beams in the exposure section and an exposure timing. The guide groove exposure voltage supplier is for supplying, in accordance with the pre-pit designation signal, to the exposure section a guide groove exposure voltage of a first power level when an inside or an outside guide groove adjacent to the pre-pits is exposed and a guide groove exposure voltage of a second power level when a guide groove not adjacent to the pre-pits is exposed. The modulator modulates a laser beam for exposing the guide groove in accordance with the guide groove exposure voltage.

Abstract: A waterproof felted material (10) has a thermoplastic polyolefin sheet (20) to which a thermoplastic fibrous polyolefin matting (30) is bonded with a portion of the fibers of the matting (40) embedded in and fused to the thermoplastic polyolefin sheet. A solidifying coating (50) may be applied to the matting.

Abstract: An apparatus for forming reinforcing structural rebar comprises: resin supply means for supplying a first resin; a first shaping die; means for impregnating a first reinforcing material with the first resin; means for pulling the resin-impregnated first reinforcing material through the shaping die to form the core of the structural rebar; material applying means for applying material for the outer cladding of the structural rebar to the core; and mold means for molding the outer cladding layer into a desired configuration on the core. The material applying means for applying the outer cladding includes means for applying an inner cladding layer over the core and means for applying an outer cladding layer over the inner layer. The inner cladding layer includes a second thermosetting resin containing a second reinforcing material, and the inner cladding layer applying means is configured so that the second reinforcing material is applied substantially unidirectionally along the longitudinal axis of the core.

Abstract: A laser beam is focused onto a substrate for texturing the substrate surface to form a multiplicity of microscopic bumps thereon, wherein the laser beam to be focused is continuously modulated at an I.sub.max /I.sub.min ratio in the range from 10 to 100 wherein I.sub.max is the maximum amplitude of pulse oscillating laser beam output and I.sub.min is the minimum amplitude of pulse oscillating laser beam output, while the minimum output of the laser beam is controlled to a level lower than the minimum energy required for creating the microscopic bumps. A magnetic recording medium having good CSS characteristics can be produced at a high production rate from the laser-textured substrate.

Abstract: A method for compression molding a resin-impregnated preform to fabricate an impact-resistance, fiber-reinforced composite fan blade for use in a high bypass turbofan engine. The method is compatible with the use of high viscosity resin systems that contribute greater impact resistance to the fan blade, but whose flow through the fan blade during molding would cause unacceptable movement of the reinforcing fibers. The method entails restricting the flow of the resin system within the preform through selective placement of a resin-impervious material on certain surfaces of the preform, so as to prevent resin loss and fiber movement during the compression molding operation.

Abstract: The present invention relates to thermoplastically formable composite materials of reinforcing fibers in a polyamide 12 matrix, characterized in that the polyamide 12 matrix consists of anionically polymerized laurin-lactam maximally containing 15 weight-% of co-monomers and selectively additives which are determined on the basis of production, processing and use. The invention furthermore relates to a process for producing these composite materials, in accordance with which an activated anionic lactam 12 melt is prepared, which penetrates the fiber arrangement in the liquid state, so that it forms the matrix for a shaped body, the activated melt is final-polymerized under the effects of temperature and pressure in a mold or a tool in such a way that the shape is achieved, and the pre-formed part is subjected to an after-shaping step under the effects of pressure and temperature, if desired.

Abstract: A method of making a toothed belt. A toothed belt is made by guiding a strip of fabric to pass through a thermosetting resin to soak it with thermosetting resin, then the soaked fabric is guided to pass through a pair of toothed rollers to form a series of toothed grooves thereon, thereafter the fabric is guided to pass around a plane roller and simultaneously rubber material is fed into the space between the outer peripheral surface of the plane roller and said fabric. Then, the fabric is wound onto a cylindrical mold having corresponding toothed grooves thereon and its two ends are glued together to loop around the cylindrical mold, then reinforcing cords and rubber sheets are covered over the fabric. Finally, the rubber material is vulcanized to form a toothed belt. Fabrics treated by the method demonstrate considerately greater flexibility or extendibility to comply with bending when under operation. Furthermore, the tooth contour of the belt will be more accurate than conventional ones.

Abstract: A method of avoiding phase discontinuities between adjacent sections of a long Bragg grating written section-by-section in an optical fibre uses masks with alignment parts additional to their writing parts. Each alignment part is a replica of a portion of the writing part of the adjacent mask. The writing of the Bragg grating produces an associated absorption grating and so, for light directed in series through the alignment part of the mask and the already-written previous section of the grating, transmission is at a maximum when the mask is moved into exact registry. Fine adjustment of mask position is made to find this condition before writing with this mask is commenced.

Abstract: It can be selected whether to form a both-side wobble groove whose both side walls wobble by irradiating two light beams while oscillating the same along the radius of a magneto-optical master disk, or to form a one-side wobble groove one of whose side walls alone wobbles by irradiating two light beams while fixing one of the same and oscillating the other along the radius of the magneto-optical master disk. Then, either a single one-side or both-side groove for tracking-use is formed by irradiating both the two light beams on a photo-resist applied on a glass substrate in accordance with address data. As a result, grooves of different types, both-side and one-side grooves, can be formed continuously in the exposing process.

Abstract: A method of continuously draw-molding a fiber reinforced plastic rod formed with a spiral groove includes the steps of arranging in parallel a plurality of reinforcing fibers under tension, impregnating an unhardened thermosetting resin in the reinforcing fibers with tension being applied to the reinforcing fibers, winding a tape having a resin impregnable property and an expandible and contractible property around a fiber bundle composed of the thermosetting resin impregnated reinforcing fibers in a spiral fashion with a winding angle being substantially equal to an angle of the spiral groove with respect to an axial direction of a rod to be molded, passing the fiber bundle with the wound tape in a heating mold provided with a hole having a cross section substantially equal to that of the rod to be molded to heat and harden the thermosetting resin, and taking up the tape thereafter.

Abstract: An automated method and apparatus is provided to mold and cure soft contact lenses. At a first station, front curve mold halves are partially filled with a polymerizable monomer. At a second station, a surfactant coating may be applied to a flange on the front curve mold half to provide subsequent preferential adhesion of any excess hydrogel to a back curve mold half at the time the mold halves are separated. At a third station, the mold halves are assembled under vacuum, and clamped to displace any excess hydrogel from the mold cavity. This clamping step firmly seats the back curve mold half, severs any excess monomer from the monomer in the cavity, defines the lens edge, and seals the cavity in a vacuum. Following assembly of the mold halves, the assembly is transported to a precure station and reclamped, and the monomer is precured with actinic radiation, such as UV, to partially cure the monomer to a gel like consistency.

Abstract: An apparatus and method is provided for producing composite reinforcement elements having high tensile strength and anchoring points for retaining the elements in concrete or masonry. The apparatus includes a creel station having a plurality of fibers, and a placement station for arranging the fibers into a multi-fiber roving. The roving is passed through a resin bath for coating the roving with a corrosion resistant material. The coated roving is heated so as to partially cure the coating material. The roving is then continuously pulled through a rotary die station which imparts a desired shape or profile to the composite element. The element is also heated in the rotary die station so as to complete the curing process.

Abstract: To produce a pultrusion which can be machined without undue strength loss bidirectional woven fiber fabric is modified to be pultrudable into a high shear strength composite member. In a preferred form of the invention the fabric is pleated in the pultrusion process to create an endless wall of stacked switch-back pleated layers which defines a box beam wall in one example, and the shaft of a bolt in another. Products produced by this process have improved isotonic strength qualities over currently produced pultrusions, which are limited to unidirectional fibers, continuous fiber mats, or alternating layers of non-woven 0.degree. and 90.degree. cloth and do not have the shear strength inherent in the pleated configuration.

Abstract: A method for performing resin injected pultrusion employing different resin materials is provided. The method comprises impregnating the interior layers of a pultrusion reinforcement pack with a first resin material, adding the exterior layers to form a pultrusion pack and impregnating the pack with a resin material substantially nonidentical to the first resin material.

Abstract: A composite storage tank is built which has double wall characteristics. A method of building the tank comprises the steps of applying a viscous resinous core material to a support surface and then winding onto, into or along with the viscous resinous core material discrete filament bundles. The resinous core material encapsulates the filament bundles, but does not significantly penetrate into an interior of the bundles. The substantially resin-free interiors provide flow paths for the ready detection of wall leakage. The resultant composite storage tank has double wall characteristics. A crack or hole in either an inside or outside surface which extends at least to the encapsulated filament bundle interiors will alert the tank's operator/owner to a leakage problem.

Abstract: Master disks for providing dies in particular for pressing optical disks, methods of manufacturing same, pressing dies obtained from such master disks and optical disks obtained from the latter and such pressing dies, the master disks consisting of a support carrying at its surface a succession of microcups representative of the information to be duplicated and consisting of a hard, conducting material reflecting in the near infrared range and selected from a zirconium, hafnium or titanium nitride or carbonitride, a hard ceramic reflecting in the near infrared range and conducting at the surface only and a hard glass reflecting in the near infrared range and conducting at the surface only.

Abstract: An energy beam is irradiated to a workpiece through a beam transmission hole defined in a mask. At that time, a relative position between an energy beam source and the mask or the mask and the workpiece is changed, so that machining depth of the workpiece is varied depending on machining portions of the workpiece, which correspond to amounts of irradiation of the energy beam. With this method, a machined product having locally different depths very easily can be made and further the product can be machined to desired depths with high accuracy by a single machining operation in a short time.

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.

Abstract: An automated demolding apparatus for reliably and repeatedly mechanically separating contact lens mold portions of a mold assembly without damaging the contact lens formed there between. Before demolding, the second mold portion is irradiated by a laser beam, which is absorbed thereby to cause a substantial temperature gradient between the second mold portion and the contact lens being demolded.

Abstract: This invention teaches a method for fabricating a microlens within a window of a laser diode assembly, and a laser diode assembly fabricated in accordance with the method. The method includes the steps of (a) providing a laser diode assembly that includes a window that is substantially transparent at wavelengths emitted by a laser diode within the assembly, the window comprising a wavelength-selective absorber of electromagnetic radiation; and (b) irradiating a portion of a surface of the window with electromagnetic radiation having wavelengths within a range of wavelengths that are absorbed by the wavelength selective absorber such that a portion of the electromagnetic radiation is absorbed for heating and melting the material adjacent to the surface region, whereby the melted material rises up above the surface to form, when re-solidified, the microlens.

Abstract: A process for preparing a matrix resin composite contains the steps of: (1) preparing a preform containing multiple layer of reinforcing material and a crosslinkable tackifier by (a) applying the tackifier onto the reinforcing material, (b) compressing the layers of reinforcing material and partially crosslinking the tackifier under a pressure sufficient to compact the tackified, reinforcing layers to a volume which is less than their volume in the finished composite part and in a manner such that at least one surface of each of the reinforcing layers is or will be, during partially crosslinking, in direct contact with the tackifier, and (2) contacting the preform with a matrix resin.

Abstract: A method and apparatus for resin injected pultrusion is provided. The method comprises injecting a resin material into a reinforcement pack at a sufficiently high pressure such that the pressure in the injection area or weir of the injection die is substantially equal to the compression pressure applied by the exit portion of the injection die. An apparatus for achieving the method is also provided.

Abstract: The present invention provides a prepreg obtained by stretching a material including, as a main component, an ultra-high-molecular-weight polyethylene having an intrinsic viscosity of 5-50 dl/g as measured at 135.degree. C. in decalin, to a total draw ratio of at least 20, subjecting the resulting stretched polyethylene material to a splitting treatment, and impregnating the resulting material with a thermosetting resin. The split stretched polyethylene material has improved adhesion to the impregnant resin and can be used as a good base material for prepreg.

Abstract: Discrete carbon or other electrically conductive fibers are added to a fluid formulation of settable resin in a bath, and a number of tows of non-conductive fibers, for example glass, are drawn through the bath, entraining and partly aligning the conductive fibers and being wetted by the resin. The tows are then bunched into a bundle, causing most of the conductive fibers and concentration zones to render the moulded product conductive to electrostatic charge.

Abstract: An endoprosthesis of compact thermoplastics including composite materials is disclosed. The endoprosthesis includes a plurality of prefabricated fibers such as carbon or aramid. Thermoplastics such as polyacrylates, polyaryl ether ketones, polycarbonates, polyether sulphones, polyethylenes or polyproplyenes are used as a binding agent. The prefabricated fibers have an internal core with predominately longitudinally oriented fibers and an enclosing covering with mutually intersecting fibers. The prefabricated fibers are cut to a length which is preferably five times their minimum diameter. The fibers are oriented substantially parallel to the major axis of the endoprosthesis. During molding and even in shallow cross- sections relative to the major axis of the endoprosthesis, each prefabricated fiber is at least partially overlapped by an adjoining prefabricated fiber.

Abstract: An optical disk records digital information in optically-reflective layers that each vary in thickness between constructive interference of a monochromatic light and destructive interference of the said monochromatic light. The difference in the intensity of a reflected light beam subjected to interferometric constructive and destructive interference is used to communicate digital data from the optically-reflective layers and a detector. The optical disk provides for multiple layers of digital information that are tuned for interferometric response at correspondingly different monochromatic wavelengths of light. Another embodiment of the present invention is a mass-production process for making such an interferometric optical disk. Another embodiment of the present invention is a variation that includes layers that are emitting or absorbing depending on dopants.

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.

Abstract: A process for preparing thermoset composite articles under relatively mild conditions includes exposing a laminate containing a partially-cured thermosettable resin and a fibrous substrate to an elevated temperature which increases over time, the elevated temperature being below the glass transition temperature of the resin but sufficient to promote further curing and increase the glass transition temperature thereof to the ultimate glass transition temperature of the resin. The temperature of exposure is generally increased at a rate which maintains the temperature within about 20.degree. C. below the glass transition temperature of the thermoset-table resin, so that cure of the resin proceeds in the glassy state. The pressure during the process is generally maintained below about 50 psi and is preferably atmospheric pressure. The process enables the production of thermoset composite articles suitable for high-performance applications without lengthy autoclave treatments.

Abstract: A lighting fixture includes a grating of discontinuities that is integrally molded in a translucent member for spatially modulating light from a light source of the fixture. A translucent lens forms an outer envelope portion of the fixture, the grating being mounted between the light source and the lens. A reflector mounted opposite the light source from the grating enhances light transmission through the grating. A semi-reflective shell member in front of the light source, used alone or in combination with a geodesicly segmented reflector opposite the light source, greatly enhances the visual effects of the fixture by projecting multiple images of the light source through the grating.

Abstract: A method for manufacturing light panels consisting of a plate shaped carrier with light conducting fibers fixed therein according to a given pattern. The method includes the steps of inserting the top end of each fiber from a fiber supply through openings in a mold. The mold is then filled with a castable plastic layer which is allowed to set to form a carrier. The carrier retains the fibers with the top ends of the fibers extending above the carrier. The top ends of the fibers extending above the carrier are melted by heat from a laser to form a melted nob at the top end of each fiber to act as a lense. A cover layer is applied on the carrier to embed the top end of each fiber and to protect the carrier. The carrier can be removed from the mold to allow the mold to be refilled with another castable plastic layer to form a next carrier for repeating the process. Removable plugs may be initially inserted into the openings of the mold to facilitate removal of the carrier at a desired angle.

Abstract: The present invention provides a reinforcing structural rebar. The rebar comprises an inner core formed by pultruding reinforcing fibers through a bath of a first resin material, the inner core typically containing at least about 40 percent by weight reinforcing fibers and an outer cladding of a corrosion resistant and reinforced second resin material.

Abstract: An optical disk records digital information in optically-reflective layers that each vary in thickness between constructive interference of a monochromatic light and destructive interference of the said monochromatic light. The difference in the intensity of a reflected light beam subjected to interferometric constructive and destructive interference is used to communicate digital data from the optically-reflective layers and a detector. The optical disk provides for multiple layers of digital information that are tuned for interferometric response at correspondingly different monochromatic wavelengths of light. Another embodiment of the present invention is a mass-production process for making such an interferometric optical disk. Another embodiment of the present invention is a variation that includes layers that are emitting or absorbing depending on dopants.

Abstract: A process is disclosed for forming a flexible, electrically conductive fabric by applying to a nonconductive flexible fibrous web substrate an aqueous solution comprising a conductive material and a binder, saturating the web with the aqueous solution, and drying and curing the web. Another process is disclosed for altering the chemical or physical properties of a resin during a production process comprising the steps of treating a fabric with an aqueous solution containing a conductive material, a binder and a resin-affecting compound; applying the treated fabric to a resin and causing the resin-affecting compound to leach from the fabric into the resin; forming an article from the fabric and the resin, and curing the article. A further process is disclosed for treating the fabric by dipping the fabric in an aqueous solution containing a conductive material, a binder, and a resin-affecting compound; nipping the fabric; and drying the fabric.

Abstract: A method of manufacturing a diaphragm of a speaker includes the steps of: 1. weaving a plurality of fibers to become a fiber sheet; 2. immersing the fiber sheet in resins; 3. spraying or inserting an enforcement material to the fiber sheet to form a combination sheet; 4. rolling the combination sheet into a flat pattern and therefore creating a tension therein; 5. drying the combination sheet, 6. putting said combination sheet into a mold and applying a high temperature thereto under a high pressure to form a cup-like configuration and 7. cutting the combination sheet into a desired configuration.

Abstract: A continuous process for manufacturing a coated fiber reinforced pultruded article or coated extrudate and the coating composition for use in this process. The coating composition includes an isocyanate resin, at least one active hydrogen-containing resin and at least one solvent having an evaporation rate equal to or less than about 0.5. The process and coating composition of the present invention produce fiber reinforced plastic articles having smooth, adherent surface coatings.

Abstract: An apparatus for forming reinforcing structural rebar comprising a core of a thermosetting resin containing reinforcing material and an outer of sheet molding compound is provided. The apparatus comprises layer reinforcing material supply, a thermosetting resin supply means, a shaping die, means for impregnating the reinforcing material the reinforcing material with resin, means for pulling the reinforcing material through the shaping die to form the core of the thermosetting resin containing reinforcing material, sheet molding compound supply, guide means for guiding the sheet molding compound onto the core, and mold means for molding the outer layer of sheet molding compound onto the core.

Abstract: A multi-vane structure for incorporation in an aircraft gas turbine engine has vanes of complex geometry made of braided fibers which are continuous about the cavities defined by the vanes. These complex geometry parts are prepared by providing a plurality of removable mandrels, stacking the mandrels along a horizontal axis in a cavity end to cavity end configuration, braiding about the mandrels, cutting the mandrels adjacent the cavity end faces, side stacking the mandrels so the faces are placed in a parallel orientation and molding. Utilizing braided fibers instead of hand lay-up woven fibers eliminates seams and produces cavities having continuous fibers about the periphery thereof which substantially increases the strength and dimensional reproducibly of the part.

Abstract: A slurry is molded from ceramic fibers and/or microparticles to form a soft felt mat which is impregnated with a sol prior to drying the mat. A catalyst for the sol is caused to diffuse into the mat by exposing the mat to the catalyst and subjecting the mat to a soak time during which the catalyst diffuses into the mat and causes the sol to gel. The sol-gel binder forms bonds so that the mat is dimensionally stabilized. The mat is dried to produce ceramic insulation, ceramic insulation having a consistent microstructure and a fully gelled sol-gel binder through its entire thickness.

Abstract: A method is provided for producing a graphic for a backlit component, such as a button for an illuminated graphic display of an automobile instrument panel. The method involves a process by which molded plastic backlit buttons are manufactured without the use of hazardous chemicals or materials, and instead utilizes laser energy to produce substantially opaque regions on the button for forming a graphics image. Backlit buttons are preferably formed from a substantially transparent polymeric material in which is present pigmentation that is reactive to laser energy. A graphic image is then created on the button by selectively exposing a portion of the backlit component to laser energy. As a result, the exposed portion becomes substantially opaque while remaining portions of the backlit component remain substantially transparent. As such, the exposed and unexposed portions of the button cooperate to produce the graphic image when the button is backlit with a suitable light source.

Abstract: The present invention provides a prepreg obtained by stretching a material including, as a main component, an ultra-high-molecular-weight polyethylene having an intrinsic viscosity of 5-50 dl/g as measured at 135.degree. C. in decalin, to a total draw ratio of at least 20, subjecting the resulting stretched polyethylene material to a splitting treatment, and impregnating the resulting material with a thermosetting resin, and a process for producing said prepreg. The split stretched polyethylene material has improved adhesion to the impregnant resin and can be used as a good base material for prepreg.

Abstract: A process for producing a composite part comprising:(i) putting short reinforcing fibers into a transfer mold;(ii) impregnation said short reinforcing fibers with a low viscosity resin;(iii) maintaining said short reinforcing fibers impregnated with by said resin in said transfer mold at a first temperature T.sub.1 known as the gelation temperature until a pasty preform is obtained whose viscosity is suitable for compression molding;(iv) removing said pasty preform from the mold;(v) placing said pasty preform in a compression mold brought to a second temperature T.sub.2, known as the compression temperature, wherein T.sub.2 >T.sub.1 ;(vi) compression molding said pasty preform; and(vii) polymerizing said pasty preform at at least a third temperature T.sub.3 wherein T.sub.3 .gtoreq.T.sub.2.

Abstract: A formable prepreg, and a method of making a formable prepreg by a pultrusion process. The method includes (a) impregnating reinforcing fiber with a thermosetting resin matrix, and (b) passing the resin impregnated reinforcing fiber through a die within which the resin impregnated reinforcing fiber is subjected to conditions sufficient to thicken the thermosetting resin matrix, to provide a formable prepreg. The present invention also provides a method of making a molded article using the prepreg of the present invention.

Abstract: An apparatus for forming reinforcing structural rebar comprising a core of a thermosetting resin containing reinforcing material and an outer of sheet molding compound is provided. The apparatus comprises layer reinforcing material supply, a thermosetting resin supply means, a shaping die, means for impregnating the reinforcing material the reinforcing material with resin, means for pulling the reinforcing material through the shaping die to form the core of the thermosetting resin containing reinforcing material, sheet molding compound supply, guide means for guiding the sheet molding compound onto the core, and mold means for molding the outer layer of sheet molding compound onto the core.

Abstract: The present invention relates to a pultrusion process for preparing fiber reinforced furan resin composites by drawing a plurality of continuous filaments through an impregnating bath of liquid furan to wet-out the filaments with the resin and a squeeze orifice for removal of excess resin and air, and continuously pulling the resin-impregnated filament through a pultrusion die to heat and cure the resin. The liquid furan resin contains a furfuryl alcohol prepolymer and a minor portion of an acid catalyst, and is maintained at a temperature of 15.degree.-35.degree. C. and has a viscosity of 500-3000 cps during the impregnating step. A postcuring treatment may be optionally employed to the pultruded fiber reinforced furan resin composites for improving their mechanical properties, which includes heating the pultruded composites at a temperature of 100.degree.-220.degree. C. for a period of 1-18 hours. Adding 1-15 wt % of mineral fillers may also improve the mechanical properties of the pultruded composites.