Joining A Plurality Of Superposed Fibrous Or Textile Layers Patents (Class 264/258)
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Patent number: 7824591Abstract: A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a core edge. A first layer of resin preimpregnated tape is wrapped continuously around the first core face, the core edge and the second core face. A thread is stitched along the first layer of preimpregnated tape. A second layer of resin preimpregnated tape wrapped continuously around the first layer of resin preimpregnated tape.Type: GrantFiled: March 14, 2008Date of Patent: November 2, 2010Assignee: Bauer Hockey, Inc.Inventor: Adam Gans
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Patent number: 7825050Abstract: A nonwoven composite has a first surface, a second surface, and a thickness extending between the first and second surfaces. The nonwoven composite comprises a plurality of natural fibers, a plurality of binder fibers, and a VOC-absorbing material. The binder fibers are bonded to or interlocked with the natural fibers. The VOC-absorbing material is dispersed within the nonwoven composite in such a manner that the density of the VOC-absorbing material in the nonwoven composite is greatest adjacent to the second surface of the nonwoven composite. A method for producing a nonwoven composite is also described.Type: GrantFiled: August 3, 2007Date of Patent: November 2, 2010Assignee: Milliken & CompanyInventors: David E. Wilfong, Wei Xiao, Gregory J. Thompson, Raymond C. Sturm
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Patent number: 7824171Abstract: An inflatable compaction tool for consolidating a composite material inside a faceted hollow or tubular mold for a composite part is made from an elastic material. The compaction tool includes relatively flat wall segments conjoined by corner segments that define a sealed chamber. The wall segments curve away from the mold surface toward the midpoint of each wall segment, so that as a pressurized fluid is introduced into the compaction tool, a component of the force exerted on the tool interior surface is transmitted through the wall segments toward the corner segments. Thus, during initial inflation, the corner segments are forced toward the corner regions of the mold before the wall segments contact the composite material, firmly compressing the composite material into the corner regions of the mold before the friction of the wall segments against the composite material inhibits expansion of the corner segments into the mold corner regions.Type: GrantFiled: October 31, 2005Date of Patent: November 2, 2010Assignee: The Boeing CompanyInventors: Steven F. Hanson, Amitabh Vyas
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Patent number: 7820092Abstract: Methods of forming an elongated composite structural member are provided. One method includes, providing a substantially elongated mandrel having an exterior surface exhibiting a desired geometry. Laying up a first ply of preimpregnated fiber reinforced material over the mandrel. Applying a force to the first ply to establish a desired amount of tension within the first ply and then pressing the first ply onto the mandrel in a conformal manner. This includes passing at least one roller over the mandrel and the first ply while maintaining the desired amount of tension within the first ply. The at least one roller is at least partially complementary in shape with the mandrel.Type: GrantFiled: November 25, 2008Date of Patent: October 26, 2010Assignee: Alliant Techsystems Inc.Inventors: Vernon M. Benson, Jason K. Slack, Todd A. Rosevear, James L. Harvey, Mark Roman, Timothy Olschewski
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Patent number: 7811498Abstract: The invention relates to a process for the production of a shaped article comprising the compression of one or more fibre layers containing polyolefin fibres. The invention also relates to shaped articles obtainable with the process according to the invention and their use in anti-ballistic applications. In the process according to the invention the fibre layers contain 0.02 to 25 wt. % of a solvent for the polyolefin. The shaped articles obtained have an improved anti-ballistic quality.Type: GrantFiled: November 7, 2007Date of Patent: October 12, 2010Assignee: DSM IP Assets B.V.Inventors: Floribertus C. H. Mokveld, Jean H. M. Beugels
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Patent number: 7811406Abstract: The present invention is directed to a method of bonding at least two surfaces together. The methods step of the present invention include applying a strip of adhesive to a first surface along a predefined outer boundary of a bond area and thereby defining a remaining open area there within. A second surface, or gusset plate, is affixed onto the adhesive before the adhesive cures. The strip of adhesive is allowed to cure and then a second amount of adhesive is applied to cover the remaining open area and substantially fill a void between said first and second surfaces about said bond area. A stencil may be used to precisely apply the strip of adhesive. When the strip cures, it acts as a dam to prevent overflow of the subsequent application of adhesive to undesired areas. The method results in a precise bond area free of undesired shapes and of a preferred profile which eliminate the drawbacks of the prior art bonds.Type: GrantFiled: October 10, 2008Date of Patent: October 12, 2010Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space AdministrationInventor: James T. Pontius
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Patent number: 7807005Abstract: A fabrication method of forming a thermoplastic composite laminate material with tailored and varying thickness in a continuous process. This process utilizes automated equipment or hand lay-up to collate parts or components into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. The consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of differing thickness from these multiple ply stacks.Type: GrantFiled: February 2, 2006Date of Patent: October 5, 2010Assignee: The Boeing CompanyInventors: Alexander M. Rubin, James R. Fox, Randall D. Wilkerson
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Patent number: 7807086Abstract: A method of strengthening a boundary region between a first portion and a second portion of a fibrous body for absorbent articles. This boundary region is provided with a pattern of compressed spots, the amount of compression being gradually increasing in a direction leading away from an edge of the first portion of the fibrous body. Also, an apparatus for performing the method and an absorbent body having a strengthened boundary region.Type: GrantFiled: November 14, 2004Date of Patent: October 5, 2010Assignee: SCA Hygiene Products ABInventor: Robert Perneborn
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Patent number: 7803302Abstract: Method of producing an oblong shell member made of fiber composite material by means of vacuum infusion, where the fiber material is impregnated with liquid polymer. A mould is applied with a mould cavity, in which a fiber insertion (3) with a first lateral face (1) and a second lateral face (2) is placed, and where said fiber insertion includes a plurality of fiber layers and a distribution layer (4), said distribution layer allowing a higher rate of flow for the liquid polymer than the fiber layers.Type: GrantFiled: November 30, 2005Date of Patent: September 28, 2010Assignee: LM Glasfiber A/SInventor: Tim Møller Hansen
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Publication number: 20100239856Abstract: A method for producing parts comprising the steps of: preparing a thermoplastic composite base; preparing build up areas on the base for in situ molded features to form a kit; inserting the kit into a compression mold; applying heat and pressure to the kit in the compression mold; and removing the finished part from the compression mold.Type: ApplicationFiled: March 20, 2009Publication date: September 23, 2010Inventors: Paul Douglas Olson, Mark Jennings, Raul Ayala, David Wharton
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Publication number: 20100239798Abstract: An electromagnetic compatible container is molded from a carbon fiber reinforced polymeric material to provide a sufficient amount of structural durability while substantially preventing equipment within the container from electromagnetic interference. In one embodiment, the container is produced from a carbon fiber reinforced polypropylene sheet material that is selectively cut to form portions of the container that define a cavity for housing the equipment. The carbon fibers may be substantially encased within the polymeric material. Further, the container may have a low surface energy combined with a high level of electrical conductivity.Type: ApplicationFiled: March 17, 2009Publication date: September 23, 2010Applicant: Environmental Container Systems, d/b/a ECS CompositesInventor: Dennis M. Becklin
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Publication number: 20100233423Abstract: The invention provides moulding materials methodology for manufacturing such moulding materials, articles moulded from such materials, kits and methodology for moulding articles using said materials, the moulding materials comprising a fibrous material comprising continuous reinforcement fibres at least some of which are cut at least one point along their length. Continuous reinforcement fibres are generally unidirectional fibres, woven, knitted, braided or stitched fibrous materials.Type: ApplicationFiled: May 21, 2007Publication date: September 16, 2010Applicant: Advanced Composites Group LimitedInventors: Thomas Joseph Corden, Jonathan Philip Grigson
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Patent number: 7794640Abstract: A method of producing a non-crimp fabric and a non-crimp fabric comprising a layup of fabric plies stitched together by a thread, at least part of which is fusible, is provided. The method can include heating the stitched plies to soften or melt the fusible thread. The use of fusible thread can act as an in situ binder within the non-crimp fabric and tension created by the unfused stitching may create channels for matrix resin infusion during manufacture.Type: GrantFiled: January 15, 2009Date of Patent: September 14, 2010Assignee: Airbus Operations LimitedInventors: Michael J Healey, Raymond Johnsen
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Patent number: 7790082Abstract: A process for the production of a panel of composite material with stiffening strips, in which a mold is draped with at least one first ply of fibers pre-impregnated with resin, there is emplaced at desired positions on said ply at least one stiffening strip, the stiffening strip as well as at least a portion of the remaining surface of the first ply is covered with at least one second ply of fibers pre-impregnated with resin, then a bladder is placed to cover the above elements, the assembly is then placed under vacuum and then in an autoclave to polymerize the resin. Before emplacement of the stiffening strip and/or of the second ply (4), there is interposed at least one layer (5) of a non-adherent material between at least one portion of the surface of the stiffening strip and one and/or the other of the plies.Type: GrantFiled: April 30, 2004Date of Patent: September 7, 2010Assignee: Airbus FranceInventors: Michel Buge, Eric Rambaud, Alain Porte, Bruno Legeay
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Publication number: 20100218470Abstract: The invention relates to a vacuum cleaner filter bag having a filter medium comprising a first layer consisting of a netting, a perforated sheet or a perforated non-woven with an air permeability of at least 10,000 l/(m2 s), and a first fibre layer consisting of man-made fibres and/or vegetable fibres and connected to one side of the first layer.Type: ApplicationFiled: July 3, 2008Publication date: September 2, 2010Inventors: Jan Schultink, Ralf Sauer
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Publication number: 20100212273Abstract: The invention relates to a vacuum cleaner filter bag having a composite material comprising a first layer consisting of a netting or a perforated sheet with an air permeability of at least 10,000 l/(m2 s), and a first fibre layer consisting of man-made fibres and/or vegetable fibres and connected to one side of the first layer.Type: ApplicationFiled: July 3, 2008Publication date: August 26, 2010Inventors: Jan Schultink, Ralf Sauer
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Patent number: 7780899Abstract: Process for manufacturing monolithic composite structures comprising providing first and second subcomponents (1, 2) of composite material, attaching an expansion compensating tooling to the second subcomponent, placing the second subcomponent along with said tooling on the first subcomponent and bonding it to the latter by means of an uncured structural adhesive, covering the assembly comprising the first and second subcomponents and the tooling with a vacuum bag, performing an autoclave cycle for curing the curable material contained in said assembly under high temperature and pressure conditions, withdrawing said assembly from the curing autoclave and removing the expansion compensating tooling to obtain the desired monolithic composite structure. The tooling for carrying out the process comprises metal L- or I-shaped beams having a rough surface adapted to be applied to the second subcomponent. The invention is useful for manufacturing aircraft parts.Type: GrantFiled: March 8, 2004Date of Patent: August 24, 2010Assignee: Airbus Espana S.L.Inventors: José Manuel Menendez, Augusto Perez Pastor
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Patent number: 7771557Abstract: The invention relates to a method for joining an uncured stringer to a structural component of an aircraft or spacecraft. The uncured stringer is supplied with at least one joining section and at least one web section. A rapidly curing low-temperature auxiliary material is deposited on web flanks of the at least one web section, which are to be supported. The at least one joining section of the uncured stringer is fitted to the structural component. Curing of the auxiliary material then takes place at a first curing temperature in order to form cured supporting elements for the web flanks of the at least one web section, which are to be supported. Curing of the uncured stringer is undertaken at a second curing temperature which is greater than the first precuring/curing temperature, and then the deposited and cured auxiliary material is removed.Type: GrantFiled: September 26, 2007Date of Patent: August 10, 2010Assignee: Airbus Deutschland GmbHInventors: Peter Sander, Hans Marquardt, Hauke Lengsfeld
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Patent number: 7767128Abstract: Method of forming a curved composite structure are provided. In one embodiment, the method includes contacting at least one ply of preimpregnated material on a first surface of a curved mandrel. The first surface of the mandrel has a first radius of curvature. The mandrel further has at least one second surface that has a second radius of curvature. A tension gradient is introduced on the ply adjacent to the first radius of curvature and the ply is then pressed over the curved mandrel to form the curved composite structure.Type: GrantFiled: November 25, 2008Date of Patent: August 3, 2010Assignee: Alliant Techsystems Inc.Inventors: Vernon M. Benson, Jason K. Slack, Todd A. Rosevear, James L. Harvey, Mark Roman, Timothy Olschewski
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Publication number: 20100189566Abstract: A composite component, such as an aerofoil component for a gas turbine engine, comprises a body and a platform which are formed from respective body and platform preforms. The body preform includes fibres which are directed laterally of the preform, forming a cavity in the end of the preform. The platform preform includes a projection constituting a deltoid filler which is received in the cavity. The projection includes a 3D woven structure of reinforcement fibres so that the cavity is occupied by fibres to give the platform a generally uniform volume fraction. A further platform preform fits over the body preform so that the lateral fibres are sandwiched between the platform preforms.Type: ApplicationFiled: November 30, 2009Publication date: July 29, 2010Applicant: ROLLS-ROYCE PLCInventor: Neil R. Harrison
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Patent number: 7758786Abstract: Decorative textured surfaces are formed on articles having curved or contoured surfaces. A reusable, flexible textured blanket is placed in a mold along with a first material charge. A pressurizer is used to both impart the texture of the blanket to the first material charge and consolidate the charge to form a textured shell. The blanket is removed from the mold and a second material charge is introduced into the mold over the shell. The application of heat and pressure consolidates the second material charge and the shell to both form and cure the completed article.Type: GrantFiled: August 31, 2007Date of Patent: July 20, 2010Assignee: The Boeing CompanyInventors: John D. Nemchick, Michael P. Kuntz, Brian L. Davis
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Patent number: 7759267Abstract: A multi-layered fiber reinforced sheet for automotive vehicle interior structural components includes, in an exemplary embodiment, a permeable fiber reinforced thermoplastic core layer having a first surface and a second surface. The core layer includes a plurality of reinforcing fibers bonded together with a thermoplastic resin, and has a density of about 0.1 gm/cc to about 1.8 gm/cc. The multi-layered fiber reinforced sheet also includes at least one first reinforcing skin applied to the first surface of the core layer, and at least one second reinforcing skin applied to the second surface of the core layer. Each first and second reinforcing skin includes a matrix of reinforcing fibers and a thermoplastic resin wherein the matrix of reinforcing fibers applied to the first surface are arranged in a bi-directional orientation and the matrix of reinforcing fibers applied to the second surface are arranged in a bi-directional orientation.Type: GrantFiled: April 5, 2006Date of Patent: July 20, 2010Assignee: Azdel, Inc.Inventors: Amy M. Conover, Scott Davis
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Publication number: 20100178842Abstract: A preferred embodiment of this invention relates to a method of manufacturing a hair-based composite material, the method comprising: manipulating a plurality of cut lengths of hair to form a web or mat of hair, and combining said web or mat of hair with a structural additive to form said composite material.Type: ApplicationFiled: June 15, 2007Publication date: July 15, 2010Applicant: SOUTH BANK UNIVERSITY ENTERPRISES LIMITEDInventor: Ronald Malcolm Thompson
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Patent number: 7754045Abstract: Three simple tools are used to both preform and mold a composite layup into a J-beam. A first composite charge is preformed into a C-channel using a first tool, and a second composite charge is formed into a Z-channel using both the first tool and a second tool. The C-channel and Z-channel are laid up between the first and second tools, following which a perform composite cap and third tool are added to complete the layup and the tool assembly. The layup may be molded using vacuum bagging techniques and subsequently cured while held in the tool assembly.Type: GrantFiled: November 14, 2007Date of Patent: July 13, 2010Assignee: The Boeing CompanyInventors: Edoardo P. Depase, Christopher V. Grubbs, Grant C. Zenkner
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Patent number: 7754126Abstract: A method of manufacturing a turbine engine component is disclosed. The method includes the steps of providing a plurality of ceramic cloth plies, each ply having woven ceramic fiber tows and at least one fugitive fiber tow, laying up the plurality of plies in a preselected arrangement to form a turbine engine component shape, oxidizing the fugitive fibers to produce fugitive fiber void regions in the ply, rigidizing the component shape to form a coated component preform using chemical vapor infiltration, partially densifying the coated component preform using carbon-containing slurry, and further densifying the coated component preform with at least silicon to form a ceramic matrix composite turbine engine component having matrix rich regions.Type: GrantFiled: June 17, 2005Date of Patent: July 13, 2010Assignee: General Electric CompanyInventors: Suresh Subramanian, James Dale Steibel, Douglas Melton Carper
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Publication number: 20100162458Abstract: The invention relates to a process for the manufacture of a shaped part comprising the steps of—forming a stack by stacking (2) or more sheets comprising mono-layers of unidirectional anti-ballistic fibers and a binder followed by placing the stack in a mould, clamping the stack in the mould with a control member closing the mould—consolidating the stack under temperature and pressure into a curved shaped part. The invention furthermore relates to products obtainable with said process, which are very suitable for use in anti-ballistic applications and include e.g. helmets, curved panels, cones and domes.Type: ApplicationFiled: March 21, 2007Publication date: July 1, 2010Inventors: Jean H.M. Beugels, William A.C. Roovers, Martin A. Es,Van, Roelof Marissen, Hen Hoefnagels
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Publication number: 20100164147Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers. The wetted fibers are arranged on pressurizable members and may be configured to include internal structural features, such as shear webs. A reinforcement stiffener may be located adjacent to at least one of the pressurizable members and the wetted fibers that form the internal structural feature. The reinforcement stiffener includes a modulus of elasticity that is substantially higher than a modulus of elasticity of the resin used to wet the fibers. In one embodiment, the reinforcement stiffener may be received in a pocket of one of the pressurizable members and may include a releasing agent that permits removal of the stiffener after the composite structure has been pressurized and cured.Type: ApplicationFiled: September 23, 2009Publication date: July 1, 2010Applicant: INVISION TECHNOLOGY, LLCInventor: William L. Rodman
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Patent number: 7736569Abstract: The present invention relates to an apparatus and method for selectively dispensing reinforcement material into a concrete component. The apparatus is capable of providing, positioning and embedding any form of rolled reinforcement materials into both prefabricated concrete components and cast-in-place concrete components which can be operated by a minimal number of personnel in a timely and economical manner, and which can be used to mass produce concrete components.Type: GrantFiled: December 4, 2007Date of Patent: June 15, 2010Assignee: Oldcastle Precast, Inc.Inventors: Kenneth Baur, Harry A. Gleich, Charles K. Gantt, Jr., W. Cecil Wilson
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Publication number: 20100135819Abstract: A method of manufacturing a wind turbine rotor blade is provided. Anticipated primary load paths within the rotor blade are predicted. Fibres of reinforcing material are dispensed onto a mould, having an orientation pattern of the fibres which is selected in dependence on the predicting step. Resin is also dispensed into the mould. A wind turbine rotor blade is provided. The blade comprises fibres of reinforcing material which are embedded in resin. The fibres are short, say in the range of 5 to 200 mm, and are orientated in dependence on an anticipated structural loading pattern of the rotor blade.Type: ApplicationFiled: January 26, 2009Publication date: June 3, 2010Inventor: Paul Hibbard
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Patent number: 7727449Abstract: Production device and method for producing fiber-reinforced plastic components comprising a semi-finished prepreg product and a dry semi-finished textile product with an aeration and deaeration chamber and an exhaust line opening into the same for producing a vacuum and a semi-finished textile product chamber to receive a dry semi-finished textile product. Into the semi-finished textile product chamber an injection line for inserting resin opens, whereby a prepreg chamber for receiving a semi-finished prepreg product is provided. The prepreg chamber is located against the aeration and deaeration chamber in an air-permeable manner and the semi-finished textile product chamber is located against it at least in areas in an air-impermeable and resin-permeable manner. Due to the air-permeable membranes, a vacuum in the aeration and deaeration chamber generates a vacuum both in the prepreg chamber and in the semi-finished textile product chamber.Type: GrantFiled: May 14, 2004Date of Patent: June 1, 2010Assignee: EADS Deutschland GmbHInventors: Torsten Lorenz, Franz Stadler, Stefan Utecht
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Publication number: 20100123264Abstract: Disclosed herein are embodiments of a multi-layer nonwoven fiber material, and related methods of manufacturing the material. In one exemplary embodiment, the fiber material includes a first layer of directionally aligned fibers together with a second layer of randomly dispersed fibers dispersed over the first layer. Consistent with one exemplary method for manufacturing a nonwoven fiber material, the method includes dispersing a first plurality of fibers horizontally in one or more predetermined directions, as well as dispersing a second plurality of fibers horizontally in random directions. In such an embodiment, the second plurality of fibers is dispersed over the first plurality of fibers. Moreover, an exemplary embodiment of a roofing shingle employing a nonwoven fiber material as described herein is as disclosed.Type: ApplicationFiled: January 26, 2010Publication date: May 20, 2010Applicant: ELK PREMIUM BUILDING PRODUCTS, INC.Inventors: Paul G. Wilson, Darrell R. Heine, John J. Andrews, Louis T. Hahn, Matti Kiik
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Publication number: 20100108596Abstract: A filtration unit intended to allow the selective elimination of target substances from a fluid such as flood or a blood component, has an outer envelope formed from two flexible sheets joined together over their periphery along a bond line so as to define an inner volume, the envelope containing a filtering medium which delimits, on both sides of the bond line, an inlet compartment of the fluid to be filtered and an outlet compartment of the filtrate, each of the compartments being provided with an element—respectively an inlet and outlet element—for bringing the compartment into communication with the outside, the elements being connected between the sheets and comprising a flow channel that passes through the bond line, the unit being characterized in that at least one channel is offset relative to the bond line towards the compartment with which the channel is in communication.Type: ApplicationFiled: April 22, 2008Publication date: May 6, 2010Applicant: MACO PHARMAInventors: Robert Duhaut, Chryslain Sumian, David Godard
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Publication number: 20100112326Abstract: A composite material member including a rubber element and a composite fiber element is manufactured by integrally combining rubber and composite fiber. A method for manufacturing the composite material member is also provided. In this method, the composite fiber element whether being thermosetting or not is disposed in a first mold of a mold. The composite fiber element is a structure of at least one fiber layer wrapped with resin. The first mold and a second mold of the mold are then closed. Finally, the cavity is filled with rubber. Different forming environments are provided according to whether the composite fiber element is thermosetting or not to form and fix the rubber element on the resin of the composite fiber element.Type: ApplicationFiled: October 28, 2009Publication date: May 6, 2010Applicant: PEGATRON CORPORATIONInventors: Chia-Ming TSAI, Yi-Chen TAO
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Patent number: 7708852Abstract: A method for producing a ballistic protective armour includes superimposing a certain number of textile layers (116) in such a way that a layer structure (114) is formed, in sewing the textile layers (116) of the layer structure to each other and in pressing the layer structure (114). Prior to a sewing process, the textile layers (116) of the layer structure (114) are pre-pressed by a pre-pressing process (30) in such a way that a preform (130), whose three-dimensional shape corresponds to a final product shape, is formed and subsequently, after the sewing process (50), the preform is exposed to a heat-pressing process (100) at a temperature greater than the temperature of the pre-pressing process (30).Type: GrantFiled: February 4, 2005Date of Patent: May 4, 2010Inventor: Egon Busch
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Patent number: 7704429Abstract: The invention relates to a method of fabricating a composite material connecting rod, the method comprising the step of cutting out a pattern presenting two opposite edges from a composite fiber fabric made up of a plurality of superposed primary plies that are bonded together in such a manner that the primary plies can slide relative to one another, rolling the pattern into a tube in such a manner that the primary plies slide relative to one another to give a chamfer shape to the two edges, and joining together the chamfer-shaped edges so that they overlap.Type: GrantFiled: November 13, 2006Date of Patent: April 27, 2010Assignee: Messier-Dowty SAInventor: Patrick Dunleavy
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Patent number: 7695662Abstract: A macrocell structure 20 having a honeycomb form is preheated to cure to a cure depth falling within a range where a flexibility of prepregs in the macrocell structure remains. Subsequently, prepregs 31, 32 are arranged along a side wall of the preheated macrocell structure 20, so as to make a preliminary structure 40. Then, the preliminary structure 40 is heated while the inside of the prepregs 31, 32 in the preliminary structure 40 is vacuumed. Thereafter, the preliminary structure 40 is heated while imparting an internal pressure thereto within a mold 5, so as to be cured, whereby a resin structure 1 is produced.Type: GrantFiled: October 30, 2008Date of Patent: April 13, 2010Assignee: Toyota Jidosha Kabushiki KaishaInventor: Hiroyuki Oyama
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Patent number: 7695661Abstract: Method for making, modifying and using machinable composite molds for use in molding composite structures. The mold includes a mold body having a tool surface that is shaped to provide the molded surface of the composite structure. The mold body is made up of at least one mold layer composed of a quasi-isotropic material composed of a plurality of randomly oriented fiber bundles or chips impregnated with a resin. The use of randomly oriented fiber chips allows post-cure machining of the mold body.Type: GrantFiled: March 9, 2009Date of Patent: April 13, 2010Assignee: Hexcel CorporationInventor: Richard A. Callis
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Patent number: 7695664Abstract: A production method for molding includes a. a first molding: depending on a shape to be molded, implementing a die feed-in on soft cloth, with the plastic that is injected in being fused and set with the cloth, for serving as a substrate layer; b. punching and trimming: punching and trimming the plastic that has been set to form a base; c. a second molding: implementing a second die feed-in on the base of a shaped product, with the injected-in plastic being fused and set with a surface of the base, to form the needed shape; d. tailoring and trimming: tailoring and trimming an edge interface between two layers of the assembled plastic to form a shaped product of a double-layer plastic on the soft cloth.Type: GrantFiled: September 27, 2007Date of Patent: April 13, 2010Assignee: Universal Trim Supply Co., Ltd.Inventor: Shih-Sheng Yang
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Publication number: 20100083893Abstract: A method for manufacturing a submerged surface, such as the hull of a marine vessel or a submerged grate or conduit, uses particles that are electrically conductive and disposes those particles on the exposed surface. The particles are held in, place by an electrically conductive composite material, such as a conductive gel coat, and a charge distribution layer is used to spread the current through all parts of the conductive outer surface.Type: ApplicationFiled: May 7, 2007Publication date: April 8, 2010Inventor: Richard E. Staerzl
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Patent number: 7691311Abstract: A glass fiber reinforced article can be manufactured by: applying a mixture of glass fiber and binder over a mold surface of a first mold section to form a glass fiber matrix, wherein the binder comprises an organic solvent based binder capable of holding the glass fiber in place at room temperature; closing a second mold section over the first mold section to form a plenum between the first mold section and the second mold section, wherein the glass fiber matrix is provided in the plenum between the first mold section and the second mold section; injecting a reactive polymer forming composition into the plenum; and allowing the reactive polymer forming composition to react and form a thermoset resin. A glass fiber reinforced article is provided according to the invention.Type: GrantFiled: June 29, 2007Date of Patent: April 6, 2010Assignee: Vec Industries, L.L.C.Inventors: Edward M. Malle, Jay J. Hood
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Patent number: 7686905Abstract: A method for reestablishing the electrical continuity of an electrically conductive layer of a composite aircraft wing damaged by a lightning strike or other mechanical event is disclosed in which a copper patch replaced the damaged section of the electrically conductive layer contained. The repair is performed by first removing any surfacers, fasteners, and damaged electrically conductive layer to expose a portion of the underlying composite skin. A copper patch having a copper foil section coupled to an unsupported film adhesive is then introduced onto an underlying composite skin opening contained within an undamaged section of a copper foil grid and covered with resin-impregnated fiberglass material. The film adhesive and resin-impregnated fiberglass material are then cured and fasteners are then reinserted within the fiberglass material, copper patch and underlying composite skin. The surface of the composite wing is then reprimed and repainted to complete the repair.Type: GrantFiled: September 6, 2005Date of Patent: March 30, 2010Assignee: The Boeing CompanyInventors: Patrice K. Ackerman, Steven D. Blanchard, Daniel J. Kovach
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Patent number: 7670969Abstract: A device for obtaining off-axis reinforcement of a woven object. The device is made up of a fixed mandrel and a rotating mandrel. The rotating mandrel is connected to the fixed mandrel by a shaft that rotates through the middle of the fixed mandrel. The shaft allows the rotating mandrel to move up and down in relation to the fixed mandrel. A portion of the woven object can be clamped to the fixed mandrel while a second portion of the woven object can be clamped to the rotating mandrel. When rotated, the rotating mandrel causes the warp fibers in the woven object to twist off the 0° direction while fill or hoop fibers remain substantially parallel to the 90° direction.Type: GrantFiled: November 19, 2004Date of Patent: March 2, 2010Assignee: Albany Engineered Composites, Inc.Inventors: Donald Blackden, Kenneth Ouellette, Michael Commander, Jonathan Goering
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Publication number: 20100044909Abstract: A method of making a tackified nonwoven sheet that includes forming a densified, tackified web by providing a rebulkable nonwoven fiber web and applying an adhesive to the nonwoven web. The densified, tackified web is rebulked to an open, lofty form by exposing the densified, tackified web to a temperature of at least 225° F. Finally, a sheet is formed from the rebulked, tackified web. In some embodiments, the so-formed sheet is a cleaning wipe configured for picking up diverse debris such as sand, dust, hair, and/or food particles. In other embodiments, the method further includes the rebulked, tackified web having an increased degree of loftiness as compared to a degree of loftiness of the densified, tackified web prior to rebulking.Type: ApplicationFiled: August 20, 2008Publication date: February 25, 2010Inventors: Thomas E. Haskett, Robert J. Maki
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Patent number: 7655168Abstract: Tools for manufacturing composite parts and methods for using such tools are disclosed herein. A method in accordance with one aspect of the invention includes manufacturing a fiber-reinforced resin part from a plurality of fibers positioned on a tool having a female mold surface. The mold surface can include a first side region, a second side region, an interior region between the first and second side regions, and transition regions between the first and second side regions and the interior region. The method includes positioning a compaction tool over the mold surface. The compaction tool includes a first pressing device and a second pressing device carrying the first pressing device. The method further includes pressing a first portion of the fibers against the transition regions with the first pressing device without generally compacting the portions of the fibers outboard of the transition regions.Type: GrantFiled: January 31, 2006Date of Patent: February 2, 2010Assignee: The Boeing CompanyInventors: Darrell D. Jones, Joseph D. Brennan, Mark E. King, Kurtis S. Willden, George D. Hempstead
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Patent number: 7651650Abstract: A machine and a method for forming composite materials are provided. The machine includes a frame and at least one forming beam attached to the frame, the at least one beam being arranged to align with a mandrel. The forming beam is pivotally segmented into at least two segments to conform to the shape of the mandrel, or alternately is bendable to conform to the shape of the mandrel. The mandrel is receivable within the frame in alignment with the forming beam. An apparatus is also provided to position a composite charge over the mandrel, and to position the mandrel within the frame. A further apparatus is provided to transport the mandrel, and to urge the mandrel toward the forming beam, forming a composite charge.Type: GrantFiled: August 10, 2006Date of Patent: January 26, 2010Assignee: The Boeing CompanyInventors: Kurtis S. Willden, Raymond N. Henderson, Gary E. Pfitzner, Surendra R. Parekh, Christopher G. Harris
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Publication number: 20100016991Abstract: The invention relates to a prosthetic product having a composite material wall moulded into the shape of a part of a body, characterized in that the wall of the prosthetic product is composed of, on one hand, an reinforcing textile including continuous length fibres, and on the other hand, a textile matrix including thermoplastic polymer fibres, preferably of continuous length.Type: ApplicationFiled: September 5, 2007Publication date: January 21, 2010Inventor: Kennet Hellberg
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Patent number: 7648661Abstract: A system and method for making and using a reconfigurable composite part mandrel operable in the manufacture of composite parts. The system may comprise an assembly fixture, a generic mandrel, a reconfigurable simulated skin, a reconfigurable frame portion, and state-changing material operable to harden into a desired configuration for forming a particular composite part. The method of forming and using the reconfigurable composite part mandrel may comprise: inserting the simulated skin within the assembly fixture, inserting or assembling the frame portion within the assembly fixture; inserting the generic mandrel into the assembly fixture; filling a cavity between the generic mandrel and the assembly fixture with the state-changing mixture to encapsulate the frame portion; hardening the state-changing mixture; and removing the assembly fixture and the simulated skin.Type: GrantFiled: August 22, 2008Date of Patent: January 19, 2010Assignee: Spirit Aerosystems, Inc.Inventor: Steven F. Hanson
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Patent number: 7641834Abstract: An intermediate product for the manufacture of a hollow fiber-composite component having a shape and dimensions, includes a three-dimensional, hollow preform of reinforcing fiber material corresponding to the shape and the dimensions with a three-dimensional reinforcing fiber structure which is formed from at least one planar, single- or multi-layer blank of two-dimensional, web-like reinforcing fiber material matching the dimensions, and a closable total cross-sectional profile with at least two hollow chambers located adjacent to each other and separated from each other by a rib-like partition. The partition is formed by an overlap region of the at least one blank which is stitched in two dimensions by a compacting seam which fixes the shape and dimensions of the rib-like partition as well as its position relative to adjacent regions of the blank and prefixes, precompacts and reinforces the reinforcing fiber material in the region of the partition.Type: GrantFiled: February 9, 2005Date of Patent: January 5, 2010Assignee: Eurocopter Deutschland GmbHInventor: Christian Weimer
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Publication number: 20090321978Abstract: A method of manufacturing a panel made of a composite material using a tool having a support on which a lay-up is performed, the lay-up producing a stack of plies of fiber prepregs, followed by consolidating the stack aiming to obtain the panel using a compacting plate arranged above the stack. The method is implemented such that a first set of polyimide films partially covering each other is located in contact with the stack of plies, between the latter and the compacting plate.Type: ApplicationFiled: September 13, 2007Publication date: December 31, 2009Applicant: Airbus FranceInventors: Didier Kurtz, Stephane Pauchet, David Bouvet, Marc Challet
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Patent number: 7638085Abstract: The Invention is a reinforced plastic sonar dome having a low acoustical insertion loss combined with sufficient mechanical strength. Acoustical and structural fibers are stochastically mixed and formed into a blended yarn. The blended yarn is woven into a blended fabric. The blended fabric is ordered into a stack having multiple layers of blended fabric. The blended fabric is incorporated into a polymer resin while the polymer resin is in liquid form using a vacuum assist. The acoustical fibers and the vacuum assist modify the acoustical properties of the resulting composite sonar dome.Type: GrantFiled: July 24, 2008Date of Patent: December 29, 2009Assignee: Materials Sciences CorporationInventor: Anthony A. Caiazzo