Abstract: A method of forming a fishing rod with at least one integrally formed support includes providing a bladder over a mandrel, wrapping a resin-impregnated material over the bladder to provide a wrapped resin-impregnated material, removing the mandrel from the wrapped resin-impregnated material, folding the wrapped resin-impregnated material onto itself at least once to form a tubular body, wherein folding the wrapped resin-impregnated material forms at least two separate bladder portions and the integrally formed support within the tubular body, placing the tubular body into a mold, and molding the tubular body to provide the fishing rod with the integrally formed support.

Abstract: Method of manufacturing wind turbine blades having composite materials is provided that includes selecting an outer mould part, selecting an inner mould part, wherein at least a part of the surface of the inner mould part comprises a compressible layer being covered by an airtight membrane, positioning the composite materials in a mould cavity between the outer mould part and the inner mould part, evacuating the mould cavity, and bonding the composite materials, evacuating the compressible layer before positioning the composite materials.

Abstract: Disclosed is a folding and shape-forming apparatus for a prepreg which includes a vacuum chamber which can generate a vacuum pressure in the inside thereof, an expanding portion disposed inside the vacuum chamber, provided with a prepreg thereon, and expanding because of the vacuum pressure inside the vacuum chamber, a heating portion disposed inside the vacuum chamber for heating the prepreg, a mandrel loaded at a portion of an upper surface of the prepreg, a first pressing portion which is brought into contact with an upper surface of the mandrel to press the mandrel, and a second pressing portion which simultaneously presses both another portion of the upper surface of the prepreg and the expanding portion.

Abstract: A method for repairing a wear-induced void associated with a surface of a component including applying a heat-cured ceramic material to the wear-induced void, wherein the heat-cured ceramic material is configured to substantially fill the wear-induced void and providing a volume of material to a bladder configured to retain the volume of material and expand in one or more directions, wherein at least a portion of the bladder is further configured to apply at least one of pressure and heat to the heat-cured ceramic material. The method further includes applying at least one of pressure and heat, via the bladder, to the heat-cured ceramic material.

Abstract: The invention relates to a method and a device for producing a structure made up of at least two bodies in a cavity of a mold defining the structure.

Abstract: A method for producing a die tool includes forming a substantially complete face plate of the die tool utilizing an additive manufacturing process, forming a support structure of the die tool independently from the face plate, and coupling the face plate with the support structure. A die tool for use in composite manufacturing includes a face plate and stiffening structure integrated with the face plate. The stiffening structure forms one or more hollow channels that transport fluid for heating or cooling during the composite manufacturing. A die tool for use in composite manufacturing includes a face plate and a support structure coupled with the face plate. A ratio of weight of the support structure to weight of the die tool is less than 0.33.

Abstract: The present invention relates to a method for manufacturing at least a portion of a sports racquet frame that comprises a step a) of providing a moldable tube structure containing a first inflatable bladder and a second inflatable bladder. The first and second inflatable bladders are positioned on opposite first and second regions of the moldable tube structure. At an intermediate region, the tube structure comprises one or more cross channels, which pass through the moldable tube structure. The method according to the present invention comprises also a further step b) of inserting said tube structure inside a mold forming a mold cavity of a desired shape. Mold members are inserted into the cross channels of the tube structure, so that the outer surface of the mold member faces the inner surface of the corresponding cross channel.

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: A press includes a pressure chamber filled with a substantially incompressible medium that at least partially encloses an elastomeric vessel filled with a substantially incompressible fluid that is in fluid communication with a pressurized source of the same fluid. Method and systems employing the press are also disclosed.

Abstract: The invention relates to a method of producing a shell member of fiber composite material by means of vacuum infusion, where the fiber material is impregnated with liquid polymer, and applying a mould (18) with a mould cavity. In the mould cavity a lower distribution layer (11) is placed. A fiber insertion (1) including a plurality of fiber layers is placed above the lower distribution layer (11). A first upper distribution layer (9) and a second upper distribution layer (10) are placed at a transverse distance of each other above the fiber insertion, so that at least a part of the first distribution layer overlaps a first zone (2) of the fiber insertion (1), and at least a part of the second distribution layer overlaps a second zone (3) of the fiber insertion (1), the first zone (2) and the second zone (3) being separated by an intermediate zone (6) neither overlapping the first nor the second distribution layer (9, 10).

Abstract: A composite sports racquet frame including a frame made of composite material, the frame including a head portion configured to receive and surround a string bed with a plurality of string segments, and a handle portion. The head portion includes a tip section on an opposite end of the frame from the handle portion, and the tip section includes a solid cross-section substantially throughout and the remainder of the head portion includes a hollow cross-section substantially throughout.

Abstract: A press includes a pressure chamber filled with a substantially incompressible medium that at least partially encloses an elastomeric vessel filled with a substantially incompressible fluid that is in fluid communication with a pressurized source of the same fluid. Method and systems employing the press are also disclosed.

Abstract: A displacement-injection molding system utilizes a plasticizing vessel with cylindrical heat transfer cores extending into the cavity of the plasticizing vessel to efficiently heat polymer granules to their injection temperature and a variable volume mold utilizing back pressure to maintain the injected polymer under pressure. A plunger for ejecting polymer from the plasticizing vessel incorporates openings for receiving the cylindrical cores. The plasticizing vessel is preferably sized to receive at least two shot sizes of polymer material to permit continuous heating of the granules of plastic material between shots as additional granules are added to replace the ejected material.

Abstract: 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.

Abstract: An apparatus and method for making a mold or mold face includes a container having at least one opening. The apparatus also includes a flexible membrane that is retained to the container that extends across the opening of the container. The apparatus for making a mold further includes support media that is disposed within the container along with a vacuum valve that is connected to the container.

Abstract: The present invention relates to a method for manufacturing at least a portion of a sports racquet frame that comprises a step a) of providing a moldable tube structure containing a first inflatable bladder and a second inflatable bladder. The first and second inflatable bladders are positioned on opposite first and second regions of the moldable tube structure. At an intermediate region, the tube structure comprises one or more cross channels, which pass through the moldable tube structure. The method according to the present invention comprises also a further step b) of inserting said tube structure inside a mold forming a mold cavity of a desired shape. Mold members are inserted into the cross channels of the tube structure, so that the outer surface of the mold member faces the inner surface of the corresponding cross channel.

Abstract: A method of forming a hollow composite construction member of the type suitable for use as building material includes providing an elongated inflatable mold assembly having a longitudinal axis, a flexible tubular bladder wall defining an elongated inflatable cavity, a reinforcing fabric positioned concentrically around the flexible bladder wall, and a flexible air-impervious outer layer positioned concentrically around the fabric. The bladder wall and the outer layer define an elongated annular space with the fabric positioned therein. Tension is applied longitudinally to the fabric and fluid is introduced into the cavity to at least partially inflate the mold and shape the fabric. The mold is shaped to a desired shape while maintaining the fabric under tension. The elongated annular space and the fabric are infused with a rigidification material. The rigidification material is hardened while maintaining the fabric in tension to form a rigid hollow composite construction member.

Abstract: A honeycomb containing a thermoplastic material, high modulus fiber and thermoset resin has process steps of fracturing the thermoset resin, bending, molding or forming the honeycomb in a mold or over a form, heating to allow flow of thermoplastic material and cooling of the honeycomb to retain the shape of the mold or form.

Abstract: 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.

Abstract: A mandrel for composite fabrication includes an open cell foam carrier and at least one vacuum bag enclosing the open cell foam carrier.

Abstract: The invention relates to an apparatus and method for moulding a substantially hollow building panel (12) of the kind having spaced opposed outer panel walls (14) interconnected by a plurality of spaced formations 16 such that adjacent formations each define a void (18) therebetween. The apparatus including a mould (20) having means to define an outer surface of least one of the outer panel walls and a plurality of spaced apart inflatable void forming plug members (26) connectable with an inflation means, disposed within the mould. The apparatus further including a means to introduce a settable wet mix into the mould.

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: A method for forming a hollow FRP article by internal pressure molding includes positioning a FRP prepreg on a periphery of an airtight internal-pressure holding tube, inserting a composite body including the internal-pressure holding tube and the prepreg into a vacuum chamber containing a forming die, evacuating the vacuum chamber in an isolation state where the composite body and the forming die do not contact each other, and clamping the forming die to bring the forming die and the composite body into contact with each other and heating the forming die with an application of pressure to an inside of the internal-pressure holding tube after completion of the evacuating step.

Abstract: 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.

Abstract: A bicycle wheel rim and a method of making a bicycle wheel rim are provided. The rim provided is made of a single part using structural fiber based material, preferably carbon fiber material, with two circumferential wings for anchoring the tire, which extend radially outwards from the two sides of the outer peripheral wall of the rim.

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: A method of making a fiber-reinforced medical balloon is described herein. The method entails pressurizing a portion of a balloon, and ejecting a fiber precursor fluid from at least one nozzle adjacent to the portion. One or more fibers are formed from the fiber precursor fluid and deposited on an exterior surface of the portion. Preferably, the fibers are polymer nanofibers, and the method is carried out using an electrospinning process.

Abstract: A method is described for forming a composite article by placing a sheet of a pliable material in a mould, injecting particles into the mould so as to force the sheet of pliable material against the interior wall of the mould, and reinforcing the pliable material.

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 apparatus comprises an upper molding box, a lower mold box, an upper flexible membrane covering an opening of the upper mold box, a lower flexible membrane covering an opening of the lower mold box, a heating system located in the upper mold box, a set of ports located between the upper flexible membrane and the lower flexible membrane capable of being used to draw a vacuum between the upper flexible membrane and the lower flexible membrane, and a displacement system located in the lower mold box under the lower flexible membrane.

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: Methods and systems for manufacturing fiber-reinforced resin parts are disclosed herein. In one embodiment, a method for manufacturing a fiber-reinforced resin part includes positioning a plurality of fibers on a mold surface of a female tool, and covering the fibers with a sealing layer. The method further includes pressing a portion of the covered fibers against an interior transition region (e.g., an internal radius) of the mold surface. While the portion of covered fibers is pressed against the interior transition region, air is removed from between the sealing layer and the mold surface to draw at least a partial vacuum between the sealing layer and the mold surface.

Abstract: A method of making a mat with a textile surface and an elastomer backing is provided. The method includes mixing elastomer crumbs and a binder, depositing the crumb/binder mixture in a layer (22), placing a textile surface element (34) on the layer to form a mat assembly, and pressing the mat assembly in a press (9) while setting the binder. The elastomer crumbs are consolidated to form an elastomer backing (2) that includes voids between the elastomer crumbs, and the textile surface element is bonded to the elastomer backing to form the upper textile layer (1) of the mat.

Abstract: The invention relates to a method for the production of semiconductor granules comprising a step in which semiconductor powders are sintered and/or melted. The powders are nanometric and/or micrometric sized.

Abstract: A system for the in situ formation of prostheses between adjacent vertebrae of a patient. The system includes a first mold adapted to be located in an intervertebral disc space between the adjacent vertebrae and at least a second mold adapted to be positioned between adjacent posterior elements. Lumens are fluidly coupled to each of the molds. One or more in situ curable biomaterials are delivered through the lumens to the molds. The at least partially cured biomaterial and the molds cooperate to maintain a desired alignment and spacing of the intervertebral disc space and the posterior elements.

Abstract: A system for producing composite or bonded metal components including: first and second pressure chambers, each pressure chamber having an elastically deformable chamber wall; means for circulating fluid at an elevated temperature and pressure through each said pressure chamber; and at least one mould assembly including at least one separate mould section providing a mould cavity within which a composite or bonded metal lay-up can be located; wherein when the system is in use, the pressure chambers are held together with the elastically deformable chamber walls located in opposing relation, the at least one mould assembly containing a said lay-up being accomodated between the chamber walls while fluid at elevated temperature and pressure is circulated through each pressure chamber such that the lay-up can be compressed and cured or formed.

Abstract: A method for making a windmill blade is provided, whereby problems with glue joints and with exposure of the workers to environmentally hazardous substances are avoided. This is effected by making the windmill blade in a closed mold with a mold core (3) inside mold parts (22, 48) for formation of a mold cavity (51), in which fiber material (45, 47) and core material (46) are placed. After applying vacuum to the mold cavity (51), matrix material (57) is injected via a filling pipe (29), which is placed at a downwardly oriented side edge of the blade during the filling. Hereby is established a flow front (61) which is used for indicating complete filling when this reaches the trailing edge of the blade and penetrates out through overflow apertures.

Abstract: A single piece co-cured composite wing is disclosed. The wing has a flying surface and structural members. In one embodiment the structural members may be a plurality of spars. The spars may have various shapes to increase the buckling strength. The spars may be wave shaped, such as a sinusoidal shape. The flying surface and the structural members are co-cured in order to form a single piece, integral wing structure. A process for manufacturing a single piece co-cured wing is also disclosed. The process may include laying out composite sheets for the flying surface of the wing. Then, the composite material of the spars is arranged around a plurality of pressurizable forms. Finally, the composite material is cured in a clamshell frame.

Abstract: A displacement-injection molding system utilizes a plasticizing vessel with cylindrical heat transfer cores extending into the cavity of the plasticizing vessel to efficiently heat polymer granules to their injection temperature and a variable volume mold utilizing back pressure to maintain the injected polymer under pressure. A plunger for ejecting polymer from the plasticizing vessel incorporates openings for receiving the cylindrical cores. The plasticizing vessel is preferably sized to receive at least two shot sizes of polymer material to permit continuous heating of the granules of plastic material between shots as additional granules are added to replace the ejected material.

Abstract: The present invention provides a balloon having a non-uniform thickness that is adapted to facilitate folding of the balloon. The balloon comprises at least one relatively thin section formed between inner and outer surfaces of the balloon, and at least one relatively thick section formed between the inner and outer surfaces. The balloon may be formed from a balloon preform that similarly comprises at least one relatively thin section and at least one relatively thick section. The shape of the balloon preform may be formed, for example, by extrusion. The balloon preform may be placed in a balloon mold having a substantially cylindrical interior surface, and blow-molded to form the finished balloon configuration. The balloon comprises a non-uniform thickness, while comprising a substantially cylindrical outer diameter both after removal from the balloon mold and in an inflated state.

Abstract: A press for rigid foam sheets with continuous adjustment of the spacing between the two press plates (1,3), in particular for sandwich panels with an upper and lower outer layer and, located therebetween, a core of rigid polyurethane foam. The lower press plate (3) is here moved into a preselected position corresponding to the panel thickness to be foamed by means of synchronously rotating threaded lifting spindles (4), assisted by weight-compensating cylinders (5). Short-stroke cylinders (6) are provided between the heads of the threaded lifting spindles (4) and the lower press plate (3). Said short-stroke cylinders have the function of dissipating the moulding force which has arisen due to foaming by moving the press plate (3) a very small stroke downwards. It is also possible, instead of the short-stroke cylinders (6), to install an air cushion system, which has a stroke of approx. 1 mm, between the press plate and the heating plate. This stroke is sufficient to dissipate the foaming pressure.

Abstract: This invention relates to a novel apparatus and process for producing thermoplastic articles. In one aspect, the invention pertains to a process for manufacturing fiberglass products using a fiberglass material consisting of fiberglass strands commingled with heat-formable polypropylene strands. A molding apparatus comprising: (a) an air pressure chamber with an open side; (b) a flange plate fitted to the open side of the air pressure chamber, said flange plate having an opening therein for receiving a mold; (c) an upper bladder associated with the flange plate and covering the opening; (d) a base pressure plate; (e) a mold positioned on the base pressure plate; and (f) a locking mechanism for securing the air pressure chamber with the base pressure plate, and balanced air pressure in each chamber during molding.

Abstract: A hot isostatic pressing method is disclosed wherein workpieces are accommodated within a high pressure vessel and the interior of the high pressure vessel is filled with an inert gas of a high temperature and a high pressure to treat the workpieces. The method includes a cooling step which is performed after maintaining the interior of the high pressure vessel at a high temperature and a high pressure for a predetermined time and in which a liquid inert gas is fed into the high pressure vessel. According to this method it is possible to shorten the cycle time of an HIP apparatus.

Abstract: A method for molding composite structures whereby a material stack including a core having first and second opposing sides is prepared. The preparing of the material stack includes applying a fibrous support layer on at least one of the first side and the second side of the core section, applying an adhesive layer on the support layer, and applying a thermoplastic barrier layer on the adhesive layer. The method also includes preparing a resin and a mold; placing the material stack in the mold; sealing the core; infusing the mold and material stack with resin; curing the structure; and removing the structure from the mold. In one embodiment, the method creates a composite aircraft wing panel.

Abstract: A method for manufacturing a composite structure is disclosed herein. The process uses a frame and selectively pressurizable forms. The forms define the interior members of the composite structure and frames define the exterior surface of the composite structure. Composite material is wrapped around the forms and the forms and composite material are placed in the frame. Selective forms are then pressurized and the composite material is co-cured together. A single piece co-cured fuselage incorporating a plurality of stiffeners is also disclosed in the application. The stiffeners are co-cured to the fuselage and may be in various patterns. The patterns may include an iso-grid pattern, and ortho-grid pattern, and a hoop-grid pattern.

Abstract: Methods for fabricating foam cored items in which the foam core is tightly encased by an outer shell. The foam core is compressed, reducing a characteristic dimension, thereby facilitating installation and/or removal of the foam. The foam is then allowed to expand to the desired size. The methods are particularly suited for fabricating foam collars that are located above the chine of a boat and extend longitudinally along the sides of the boat to provide stabilization for the boat during high performance maneuvering and/or provide a fendering system.

Abstract: An imprint process comprises the step of aligning a substrate, supported on a first support member, with a template, supported on a second support member. The substrate has at least one essentially plane surface provided with a moldable film. The template has at least one essentially plane surface provided with a relief pattern. The relief pattern is adapted to interact with the moldable film. The process further comprises the step of arranging a sealing gasket between the template and the second support member, such that a pressure cavity is defined by the second support member, the template and the sealing gasket. The process also comprises the step of applying a static gas pressure to the pressure cavity, in order to provide a pressure between the template and the substrate. The pressure is sufficient to form a pattern in the moldable film. An imprint device is also disclosed.

Abstract: A method of producing a molded article including the step of inserting an expandable and contractible hollow elastic pressing member (2) inside a hollow molded article placed in a drying mold (8) and feeding a fluid in the elastic pressing member (2) to expand the pressing member (2) thereby to press the molded article toward the inner surface of the drying mold (8), wherein the molded article is pressed onto the inner surface of the drying mold (8) by the elastic member (2) in the expanded state while exchanging the fluid in the elastic pressing member (2).

Abstract: A connector element for connecting frame parts at a joint location in a bicycle frame is made of a single part of structural fiber based material, typically carbon fiber material, after reticulation in a mold exploiting the expansion of a core on which windings of fiber fabric material are provided, to obtain the application of a uniform radial pressure on the layers of fiber based material. In one embodiment, the connector element defines a bicycle bottom bracket and tubular extensions extending therefrom for connection to elements of the bicycle frame.

Abstract: A composite lined tube is disclosed having end couplings. The tube includes a resin impregnated fiber preform pressed progressively along an inner wall of the tube. The tube may further include an inflatable bladder inserted into the tube. The bladder is adapted to inflate along a length thereof on application of increasing pressure to the interior of the bladder. The bladder has disposed on its exterior surface the fiber preform impregnated with resin, which is adapted to fit within the tube. The bladder is then inflated along its length by applying increasing pressure to the bladder. The preform is clamped to a shoulder of one of the couplings at another end of the tube, and the end of the preform is trimmed to conform to the shoulder. Pressure is maintained in the bladder while curing the resin.