Abstract: A manufacturing method of a color filter substrate includes forming a black matrix on a substrate, the black matrix including first, second, third and fourth openings, forming first, second and third color filter patterns in the first, second and third openings, forming an overcoat layer on the substrate, disposing a soft mold on the organic material layer, the soft mold including first depressed portions and a second depressed portion, the first depressed portions corresponding to the black matrix, and the second depressed portion corresponding to the fourth opening, wherein a first depth of the first depressed portions is larger than a second depth of the second depressed portion, applying pressure to the soft mold such that the first and second depressed portions are filled with the overcoat layer, first curing the overcoat layer, detaching the soft mold from the overcoat layer, and second curing the overcoat layer.

Abstract: The present invention relates to a method for preparing a biodegradable piece for medical use including the steps of: a) preparing a mixture including glycerol and sebacic acid, b) pouring said mixture into a one-piece mould made of elastic material, c) placing the mould containing said mixture on a support, d) placing the support into a chamber with controlled temperature and vacuum level until a polymer having the desired consistency is obtained, e) removing the support from the chamber and allowing it to cool down to room temperature, and f) removing the piece thus obtained from the mould.

Abstract: A method is disclosed for forming a candle having the steps of providing a mold device having a unitary, one piece, seamless body capable of being used as a stand alone device having a hollow, three-dimensional shape with at least one opening therein; the body being made from a uniform material which is malleably reusable and capable of flexation during demolding, and which returns to its original shape after each demolding via shape memory, and having an axis extending vertically there through, wherein the body yields a seamless product; populating the mold with the desired candle material and volume thereof; and separating the mold from about the candle by peeling back the mold.

Abstract: A method of molding a composite article includes providing a first floating mold that has a fluid backing, wherein the fluid defining the fluid backing is stored in a fluid chamber positioned beneath the first floating mold, providing a second non-floating mold that does not include a fluid backing, and sealing the first floating mold to the second non-floating mold to define a molding chamber thereinbetween.

Abstract: 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.

Abstract: A method for manufacturing microneedle structures is disclosed using soft lithography and photolithography, in which micromold structures made of a photoresist material or PDMS are created. The micromold manufacturing occurs quite quickly, using inexpensive materials and processes. Once the molds are available, using moldable materials such as polymers, microneedle arrays can be molded or embossed in relatively fast procedures. In some cases a sacrificial layer is provided between the forming micromold and its substrate layer, for ease of separation. The microneedles themselves can be solid projections, hollow “microtubes,” or shallow “microcups.” Electrodes can be formed on the microneedle arrays, including individual electrodes per hollow microtube.

Abstract: A manufacturing process that comprises placing an article within a particulate medium (4), the article being provided with a molded body (8) of small ceramic particles. On application of heat and pressure the small ceramic particles are pushed between the particulate medium (4) to permit localized deformation of the article (2).

Abstract: A tool assembly including a male tool including an inner shape tool including a bag having a connection connectable to a depressurization source for providing a vacuum in the bag such that beads therein form a body of firm cohesion providing the inner shape tool rigid. The male tool further includes a flexible, hollow curing support arranged around the rigid inner shape tool, the inner shape tool is arranged to be removable from the flexible, hollow curing support by rupturing the vacuum.

Abstract: Disclosed are an apparatus and method for molding an object. An object is compressed by an upper mold and a lower mold base part to form a top surface of a product, and the upper mold and the lower mold base part descend in a state where the object is compressed to form a lateral surface of the product through lateral surfaces of the upper mold and a lower mold.

Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components, which are assembled to provide a structure that is sufficiently strong to maintain the spar shape during pre-cure lay up, compaction and curing of the composite material. The multiple components used to form the mandrel can be separated from each other and easily removed from the spar either before or after curing of the composite material. The mandrel components can then be re-assembled and re-used to form additional composite spars.

Abstract: The invention relates to a hand access laparoscopy device having a gelcap, a retainer, a sleeve and a retention ring. The gelcap includes gel that is bonded to a cap. The cap includes an inner cylindrical wall to which the gel in bonded, thereby providing a sealing area between the device and the wound in a body wall. By securing the gel to the inner cylindrical wall, the thickness of the gel and corresponding cap is minimized along with the overall footprint of the device. With the gel thickness reduced and able to be substantially flush, the “doming” phenomenon produced by insufflation of a patient's abdomen is reduced.

Abstract: A method and an apparatus facilitate the processing of a core structure for a composite sandwich structure. The core has an open three-dimensional structure and is not self-supporting due to an insufficient strength or stiffness. The method involves temporarily providing a support arrangement on the core structure to mechanically support and stabilize it, then subjecting the supported core structure to the desired processing, and then separating and removing the core structure and the support arrangement from one another. The processing can involve immersion into a processing liquid such as a curable resin, or mechanical machining operations. The support arrangement preferably includes a core impression that is surfacially form-fitting on a structured surface of the core structure. The apparatus includes a support arrangement including a core impression to be disposed on a surface of the core structure. The core impression may be formed of a polymer, a metal, or a casting material.

Abstract: A carrier mold having prongs that produces shaped tampons is provided. When subjected to pressure the prongs of the carrier mold flex to completely or substantially close one end of the carrier mold. A method of forming a shaped tampon using the carrier mold is also provided.

Abstract: Compositions containing at least one liquid epoxy resin, at least one solid epoxy resin, at least one propellant, at least one curing agent and at least one mica-containing filler produce expandable, thermally curable binder systems which may be used without the addition of hollow glass beads for the production of stiffening and reinforcing laminates and for the production of stiffening and reinforcing moldings. Said laminates according to the invention are suitable for the stiffening and reinforcing of components, in particular in the automotive industry, such as car body frames, doors, boot lids, engine bonnets and/or roof parts. In addition, the mouldings that may be produced from said binders are suitable for the stiffening and reinforcing of hollow metal structures, in particular of hollow car body parts such as body frames, body supports and posts or doors in the automotive industry.

Abstract: Novel polymer shrink tubes, such as fluoropolymer shrink tubes and novel uses thereof. The polymer shrink tubes include at least one three-dimensional pattern formed along at least a portion of the inner surface of the tube. The polymer shrink tubes can be used for, for example, embossing a pattern into a polymer tube. Further use includes, for example, forming a catheter with at least one channel located in the catheter wall.

Abstract: 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.

Abstract: A fiber structure for forming the reinforcement of a part to be made is placed in a mold (22) having at least one wall formed by a flexible membrane, and then a resin composition is injected into the mold, the composition having a volatile material content of less than 25% by weight and being at a temperature of a value such that its viscosity lies in the range 0.1 Pa·s to 0.3 Pa·s. The resin is polymerized in the mold placed in an enclosure (20) with temperature being raised progressively and with polymerization including at least a final stage of polymerization under pressure in order to obtain a composite material part presenting residual porosity of less than 11% by volume.

Abstract: A method for making a preform includes creating a pressure differential between an inside and an outside of a perforated shape memory polymer mandrel in its temporary shape. The pressure differential is such that pressure outside the perforated shape memory polymer mandrel is greater than pressure inside the perforated shape memory polymer mandrel. The perforated shape memory polymer mandrel has i) a predetermined preform shape as the temporary shape and ii) a shrunken shape as its permanent shape, wherein the shrunken shape is configured such that it is removable from the predetermined preform shape. The method further includes depositing, as the pressure differential is maintained, at least one material onto a surface of the perforated shape memory polymer mandrel. The at least one material is set in the predetermined preform shape, thereby forming the preform.

Abstract: Provided are, among other things, systems, methods and techniques for manufacturing sheet material. In one representative embodiment, a sheet of fabric material is positioned across a patterning template that has a number of openings; and the sheet of fabric material and the patterning template are fed through an extrusion device in which extrusion material coats the fabric material and forces the fabric material into the openings in the patterning template, thereby producing a composite sheet material.

Abstract: A method and apparatus for producing a product using a substantially flat mold shell is provided. A substantially flat mold shell converted from a 3-dimensional mold. The substantially flat mold shell has open ends. When the open ends are brought proximate to each other, the substantially flat mold shell has the shape of the 3-dimensional mold. A product having the shape of the 3-dimensional mold is formed from the substantially flat mold.

Abstract: 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.

Abstract: The present invention is directed towards a method and a system of expelling a gas positioned between a substrate and a mold, the substrate and the mold further having a liquid positioned therebetween.

Abstract: A method for making a concrete mixing drum includes forming a first layer of at least one polymeric material having a surface providing at least a portion of a barrel wall of the drum and a spiral mixing blade projecting from the wall on an inner surface of the drum and forming a second layer on the formed first layer.

Abstract: The present invention relates to apparatus and methods of vibration. In particular, the present invention relates to apparatus and methods of vibration for tooling in a structure, such as, for example, a fuselage. In one implementation, the tooling comprises at least two conductors that create a force to vibrate the media in the tooling, which improves the compaction of the media in the tooling and the extraction of the media from the tooling. Other implementations may be used for compaction and/or extraction of the media in the tooling.

Abstract: A method of pre-applying a bolster assembly to an interior trim part includes the steps of applying a base skin layer to a groove of a first nest, applying a bolster skin layer to a second nest, positioning the first nest in an open position, and inserting a leading edge of a bolster skin layer in the groove of the first nest when the first nest is in the open position until the bolster skin layer engages the base skin layer. The bolster assembly can be attached to the interior trim part by a Foam-In-Place (FIP) or Low-Pressure Molding (LPM) operation. The interior trim part may comprise a dashboard garnish, an instrument panel (IP), a door panel, and the like. A boss locating portion can be integrally formed within the base skin layer and is used for locating the bolster assembly on the interior trim piece during the manufacturing process.

Abstract: An elastomeric stamp is used to deposit material on a non-planar substrate. A vacuum mold is used to deform the elastomeric stamp and pressure is applied to transfer material from the stamp to the substrate. By decreasing the vacuum applied by the vacuum mold, the elasticity of the stamp may be used to apply this pressure. Pressure also may be applied by applying a force to the substrate and/or the stamp. The use of an elastomeric stamp allows for patterned layers to be deposited on a non-planar substrate with reduced chance of damage to the patterned layer.

Abstract: An apparatus for molding an article such as pre-cast, cement or concrete blocks, bricks, pavers, tiles and the like including a deformable mold and a movement imparting device. The deformable mold includes compartments or cavities for receiving material therein that is to be molded.

Abstract: The present invention provides for an improved device for molding keyhole sipes larger in size, i.e. sipes having a wider passage, than currently being formed in treads that will avoid damaging the tread during formation and removal thereof from a mold. The device includes an elongated deformable body member having a blade extending in a direction away therefrom and substantially along the length thereof. The body member also includes a stiffening member securely fixed in position therein that extends substantially the length thereof. The stiffening member provides a desired rigidity to the deformable body member, thereby limiting flexion along its length under the stress of a rubber formulation when the mold is closed during the molding process. Also, the deformable body member provides low stress on the tread when a slit of the keyhole sipe is pulled around the body member during removal of the tread from a mold.

Abstract: The present disclosure relates to a process for making a seamless tube from a liquid. A mandrel may be provided having a longitudinal axis, an outer surface and a length. A liquid material may be applied to the outer surface of the mandrel by one or more doctor blades, spaced apart from the mandrel outer surface and inclined at an angle ? with respect to the mandrel longitudinal axis, which may be moved along the longitudinal axis of the mandrel while rotating the mandrel around its longitudinal axis. One or a plurality of fingers may overly the mandrel and be positioned upstream of the one or more of blades, relative to the direction of movement of the blades along the longitudinal axis of the mandrel. The liquid material may then be converted to form a seamless tube.

Abstract: 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.

Abstract: The present invention relates to a substrate-supported process for continuous and automated manufacturing of microfibrous fuel cells and other electrochemical cells. Specifically, a removable substrate layer is formed around an inner current collector, followed by sequentially coating multiple structure layers, such as the inner catalyst layer, the membrane separator, and the outer catalyst layer, over such removable substrate layer, and subsequent removing such removable substrate layer, so as to form a lumen around the inner current collector, to allow passage of fluid therethrough. The removable substrate layer preferably comprises a water-soluble polymer, such as polyvinyl pyrrolidone (PVP), polyvinyl alcohol (PVA), or polyethylene glycol (PEG).

Abstract: The present invention is directed towards a method of expelling a gas positioned between a substrate and a mold, the substrate and the mold further having a liquid positioned therebetween.

Abstract: The invention disclosed herein relates to hollow fiber reinforced composite material parts having one or more selectively positioned core, structural insert, or veneer pieces integrally associated therewith.

Abstract: A molding station and method comprising a hopper having a mouth closable with at least a lower door and a mold to be filled, the hopper and the mold being movable to a filling position in which the hopper is closed by the lower door; the lower door then opening to allow an amount of moldable material to be released into the mold; the mold being made in a deformable material, so that an interior volume of the mold is temporarily reduced when releasing the moldable material into the mold.

Abstract: The present invention is directed towards a method of separating a mold, included in a template, from a layer disposed on a substrate, the method including, inter alia, applying a separation force to the template to separate the template from the layer; and facilitating localized deformation in the substrate to reduce the separation force required to achieve separation.

Abstract: A molding method includes inserting a preform having a predetermined part shape into an external mold having the predetermined part shape. The preform has therein a perforated shape memory polymer mandrel in its temporary shape, and a bladder positioned within the perforated shape memory polymer mandrel. The shape memory polymer mandrel has i) the predetermined part shape as the temporary shape and ii) a shrunken shape as its permanent shape, wherein the shrunken shape is configured such that it is removable from the predetermined part shape. The method further includes configuring the bladder such that it substantially blocks perforations of the mandrel in its temporary shape, injecting resin into the external mold between an inner surface of the external mold and an outer surface of the preform such that the resin impregnates the preform, and curing the injected resin, thereby forming a molded part.

Abstract: An arrangement and method are provided for supplying material to production equipment for ceramic products. The arrangement comprises a first unit that can be at least partially surrounded by a second unit to which it is secured via its outer surface. The second unit can be designed so that it can be fed forward and divided by the production equipment. The first and second units can be arranged to facilitate silhouetting in at least the first unit and to facilitate the creation of at least one securing part between the first and second units. The securing part can comprise one of a combination of the material of the second unit with a joining material and a combination of the material of the first unit with the joining material.

Abstract: Process for continuous manufacture of latex foam rest articles such as mattresses, cushions and the like comprising a part able to participate to the manufacture steps and to remain embedded in the article with consequent improvements of final performances. A flexible perforated band, preferably a flat polymeric material net with longitudinal and cross reinforcement members, is placed over a foam laying surface provided with protuberances and in continuous advancement between a foam laying station and an unlimited length article extraction station. The latex foam passes through net holes forming an upper portion and a lower portion relative to said net. The net continuously opposes contraction forces and weight force exerted from upper portion on lower portion. The unlimited length article is subjected to successive cross cuts originating rest articles wherein a foam embedded net is arranged on ends of recesses originated by the protuberances.

Abstract: A process for producing a polymer optical waveguide including: 1) preparing a rubber mold having a composite layer structure in which a rubber layer which has a concave portion corresponding to an optical waveguide core and contains a rubber mold-forming curable resin is buried in a rubber layer-forming concave portion of a rigid substrate having the rubber layer-forming concave portion; 2) bringing a cladding substrate into close contact with the rubber mold; 3) filling the concave portion of the rubber mold, with which the cladding substrate has been brought into close contact, with a core-forming curable resin; 4) curing the filled core-forming curable resin; 5) removing the rubber mold from the cladding substrate; and 6) forming a cladding layer on the cladding substrate on which the core has been formed.

Abstract: Disclosed is a mold for the preparation of recipient blocks, made from silicone, and a method of constructing a mold for the preparation of recipient blocks, comprising: charging a structure equipped with a mold in the form of a recipient block with silicone; curing the silicone; and separating the silicone mold for the preparation of recipient block from the structure. Also, a method is provided for preparing a recipient block, comprising: positioning the mold for the preparation of recipient blocks within a base mold; charging the base mold with a liquid material for the recipient block; solidifying the material and separating the base mold from the mold for the preparation of recipient blocks and the solidified material; and separating the mold for the preparation of recipient blocks from the solidified recipient block.

Abstract: An aircraft stringer lay-up assembly is provided comprising a first mandrel element having a first mandrel material with a first mandrel coefficient of thermal expansion. A composite ply assembly is laid up onto the first mandrel element to generate a primary lay-up surface. The composite ply assembly comprises a first primary fold-over portion folded onto to the first mandrel right end surface. A second primary fold over portion folds over to the first mandrel left end surface. The first mandrel coefficient of thermal expansion is adapted such that the first mandrel is movable between a first mandrel normal condition and a first mandrel heated condition where the first mandrel right end surface and the first mandrel left end surface move away from each other. The first primary fold-over portion and the secondary primary fold over portion are thereby moved such that wrinkles are pulled out of said primary lay-up surface.

Abstract: A die for forming a lost wax ceramic core allows the formation of non-parallel separating spaces between adjacent portions of the core. The core will eventually form cooling channels in an airfoil. The die for forming the core includes a plurality of moving parts having rib extensions. At least some rib extensions are non-parallel to form the non-parallel spaces. The die includes two main die halves that come together to form several of the spaces. Inserts move with those die components and come together to form other spaces. At least one of the inserts contacts surfaces on one of the die halves, such that the non-parallel spaces are formed.

Abstract: A method and device for removing the bulk of the casting investment surrounding a pressed ceramic dental appliance.

Abstract: A radiator core support is made by an insert injection molding method. Four core members shaped in a triangular prism are built into a quadric-prism core and inserted into a rectangular tube, an upper radiator core support member. Then, an outwardly pressing member is inserted into a longitudinal slanted hole of the core to move and contact its members to the inner surfaces of the tube. The tube is located in a mold, into which molten molding material is injected. The tube is overmolded at the tops of a hood lock stay, and right and left side support members, being integrally formed out of resin. After cooling, the method includes drawing the pressing member from the core; then the core from the mold; and the molded part is removed from the mold.

Abstract: A three-dimensional model and its support structure are built by fused deposition modeling techniques, wherein a thermoplastic material containing silicone is used to form the support structure and/or the model. The thermoplastic material containing silicone exhibits good thermal stability, and resists build-up in the nozzle of an extrusion head or jetting head of a three-dimensional modeling apparatus. The silicone contained in a support material acts as a release agent to facilitate removal of the support structure from the model after its completion.

Abstract: Apparatus and methods for processing composite components using an elastomeric caul are disclosed. In one embodiment, a method of curing a prepreg on a mandrel includes providing an elastomeric caul over the prepreg; providing a vacuum bag over the prepreg and the caul, with the caul between the prepreg and a film of the vacuum bag; and stretching the elastomeric caul over the prepreg while drawing down the vacuum bag over the caul. The caul is stretched to fit snuggly over the prepreg to reduce fiber deformation and wrinkling during curing.

Abstract: A locking mechanism for an enclosure is provided. The enclosure comprises a base including a locking groove formed therein, and a lid pivotally coupled with the base having a lock bore formed therein. The lock mechanism is mounted in the lock bore and includes a pin that is selectively positioned within the locking groove to secure the lid to the base. Also provided is a molding device and method for forming the lock bore. The mold device includes a base member with a pair of arms having a mold protrusion and a lower cam surface. The molding device also includes a housing having a pair of mold protrusion openings. The mold protrusions selectively extend outwardly through mold protrusion openings when a wedge engages the lower cam surfaces on the arms, wherein the arms spread apart from one another to form a pair of snap grooves in the lock bore.

Abstract: A method of manufacturing a composite airfoil includes the step of providing a core made of a metal or ceramic material. A plastic airfoil portion is molded to envelope at least a portion of the core.

Abstract: A process of forming a resistive device such as s load resistor or a heater is provided that includes forming a dielectric layer onto a substrate, a target, or an adjacent functional layer, wherein the dielectric layer in one form defines a single layer of dielectric tape. The dielectric tape is laminated to the substrate, the target, or the adjacent functional layer through a single predetermined cycle of pressure, temperature and time, and then a resistive layer is farmed on the dielectric layer, and a protective layer is formed over the resistive layer.

Abstract: A process for casting three-dimensional parts and sacrificial models from casting compounds forced by pressurized inert gas into transparent molds that are supported by transparent mold frames. The casting compound incorporates radiation activated photo initiators which cause polymerization and curing of the compound within the mold. An automated casting system is anticipated which is enabled by the use of very soft, stretchable and deformable material for the mold body and supporting the mold with radiation transparent mold frames. Oxygen and other gases in the atmosphere react with some casting compounds to create a sticky film on mold cavity walls which causes difficulty when removing a casting from a mold. This problem is eliminated by purging the mold cavity with an inert gas between casts.