Abstract: 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.

Abstract: A mold assembly or system includes a moldbase that holds mold inserts and has embedded fluid lines to facilitate cooling during part formation. Mold inserts combine to form mold cavities that receive carbon fiber and resin components to form a carbon composite based part. A permanent release coating along a mold component surface that contacts the carbon fiber and resin components facilitates the release of the finished part from the mold component. Guide pins and guide pin receiving holes facilitate accurate alignment of mold components. Ejector pins within respective ejector pin shafts help eject a finished part from a respective mold component. An ejector pin shaft cover transfers force from an ejector pin to eject a finished part and also prevents substantial passage of resin into the ejector pin shaft. A fluid actuated ejection system provides fluid based mechanical forces to the ejector pins to facilitate finished part ejection.

Abstract: A method of manufacturing a foam having a negative Poisson's ratio comprising the steps: placing a pad 12 of open cell polyurethane foam on a moulding surface 4; placing a flexible membrane 18 over the exposed surface of the foam to create a sealed chamber 20 between the moulding surface 4 and the flexible membrane 18 in which the foam pad 12 is disposed; applying an isostatic pressure difference between the inside and the outside of the chamber 20 thereby collapsing the foam pad 12 between the flexible membrane 18 and the moulding surface 4; heating the foam pad 12 to a predetermined temperature, and subsequently cooling the foam pad 12 while collapsed.

Abstract: A method of making a tool for curing a composite layup and a method of removing air and volatiles from a composite layup during curing. The tool includes a tool body having a surface adapted to support a composite layup and includes an integrated breather for allowing removal of air from the layup during curing.

Abstract: Methods for producing in-situ grooves in CMP pads are provided. In general, the methods for producing in-situ grooves comprise the steps of patterning a silicone lining, placing the silicone lining in, or on, a mold, adding CMP pad material to the silicone lining, and allowing the CMP pad to solidify. CMP pads comprising novel groove designs are also described. For example, described here are CMP pads comprising concentric circular grooves and axially curved grooves, reverse logarithmic grooves, overlapping circular grooves, lassajous grooves, double spiral grooves, and multiple overlapping axially curved grooves. The CMP pads may be made from polyurethane, and the grooves produced therein may be made by a method from the group consisting of silicone lining, laser writing, water jet cutting, 3-D printing, thermoforming, vacuum forming, micro-contact printing, hot stamping, and mixtures thereof.

Abstract: A material forming apparatus and method for shaping a material to a forming tool having complex contours. The material forming apparatus may comprise a bladder sealed to a support structure, cooperatively forming a hollow space therebetween into which air or another gas may be pumped to inflate the bladder. The forming tool may comprise a protrusion of any shape to which the material may conform. The material may be placed between the bladder and the protrusion and the support structure may be actuated toward the forming tool. As the support structure progresses toward the forming tool, an area of material pressed against the protrusion by the bladder increases in an outward direction. A pressure regulator may regulate an amount of pressure applied to the material by the bladder as the bladder presses the material against the forming tool.

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 thermal and vacuum assessment method includes providing a composite part having a repair area, installing a vacuum bag over the repair area, drawing a vacuum on the vacuum bag, testing for air leaks in the vacuum bag, heating the vacuum bag and obtaining a thermal image of the repair area.

Abstract: A helical tool (1?, 1?) having a rigid outer helical support surface (2) is used as support for a non-rigid material for producing a hollow elongated member onto and as an integral part with a surface member (3) in manufacturing of a surface member having at least one hollow elongated stiffening member integral therewith.

Abstract: In one aspect, the invention is directed to an efficient and economical process for dispersing fiber in water and clay. In another aspect, the process for dispersing fiber in water and clay is used in methods of making fiber reinforced composite products. In another aspect, the dispersed fiber/clay material is formulated to make products which include, but which are not limited to, fiber reinforced thermoplastic composites, paperboard products, kitty litter, and/or lightweight building materials comprising fiber.

Abstract: A plastic sheet having cloth-like appearance and thermoplasticity and provided with melt patterns in the sheet face, the melt patterns formed in a predetermined arrangement under an elongating condition of the plastic sheet so as to form convex-concave wrinkles in regions between neighboring melt patterns in the plastic sheet under an un-elongating condition.

Abstract: Two kinds or more of resin films having different surface roughnesses are pasted to an outer surface of a side portion of an unvulcanized tire, the unvulcanized tire is vulcanized and molded in a state of pasting the resin films, thereby, a pneumatic tire provided with two kinds or more of the resin films at the outer surface of the tire side portion to be able to be exfoliated therefrom is fabricated.

Abstract: A system for molding is provides and includes a first mold portion and a second mold portion. The first and second mold portions facilitate formation of a molded panel. A first sheet is inserted between the first mold portion and the second mold portion, such that the first sheet facilitates removal of the molded panel from the first mold portion.

Abstract: A man-made, molded article is provided. The article includes a profile including a planar wall, and an adjacent integral molded depression having a contoured wall extending downwardly from the planar wall. The contoured wall includes a bead portion, a cove portion, and a ledge between the bead and cove portions. The articles are stackable, one above another for transport, in a nestable relationship in which multiple contact zones are present between the contoured walls of an adjacently stacked pair of the molded articles. The contact zones include an arcuately extending contact interface zone between the bead exterior and interior surfaces. The depression has a substantially uniform thickness varying by no more than about +1 percent to about ?11 percent in relation to a thickness of the planar wall. Related methods and assemblies are also provided.

Abstract: A method for producing an endless belt includes partially covering a circumferential surface of a cylindrical mold with a covering film member nonadhesive to the mold by fixing the covering film member with a fixing member, applying a resin material to the circumferential surface of the mold, curing the resin material to form a resin film, and removing the resin film from the mold by blowing a gas into a gap between the circumferential surface of the mold and the covering film member.

Abstract: Disclosed is a method of micro/nano imprinting, which applies soft mold, pre-shaping sealing film, and soft holder arrangements to the micro/nano structure imprinting process of the curved substrates. The method of the present invention can prevent the curved surface from crumbling, which may result from high gas pressuring, and can obtain uniform imprinting pressure distribution throughout the whole curved substrate. Moreover, replicating micro/nano structures onto double-sided curve, both convex and concave, surfaces can also be achieved.

Abstract: The present invention relates to a method and a device for placing at least one material layer onto a relief mold for producing a composite material. Thereby, an elastically-reversibly deformable body with a surface relief that is designed to correspond to the relief mold is pressed against the material layer, as a result of which the surface of said body is deformed, and the material layer can be picked up. As a result of its elastically-reversible characteristics the body subsequently deforms back to its initial state so that the material layer can easily be placed onto the relief mold.

Abstract: Provided is a release film for producing a light emitting diode having desired concaves and convexes accurately transferred directly to the surface of a resin-sealed portion, at a low cost and in high yield, and a process for producing a light emitting diode. A release film 10 having a plurality of convex portions (convex stripes 12) and/or concave portions (grooves 14) formed on the surface is used as a release film to be placed in a cavity of a mold for forming a resin-sealed portion to seal a light emitting element of a light emitting diode.

Abstract: There is provided a nanoimprint apparatus. The nanoimprint apparatus transfers a pattern formed on a surface of a mold to a transfer layer which is formed partially or entirely on a side surface of a substantially cylindrical or columnar substrate. The nanoimprint apparatus includes: a first jig which is in contact with the substrate 102; a second jig which rotatably supports the first jig; a press unit which is connected to the second jig to press the substrate on the mold 104 through the first and second jigs; and a movable holding unit which holds the mold and moves the mold 104 in a direction substantially perpendicular to a pressing force.

Abstract: A method and device for shaping of an article of composite material. The method includes arranging a blank of composite material on a top surface of a forming tool. A portion of the blank is arranged to protrude outside the top surface of the tool. At least one support is arranged in contact with an underside of the protruding portion of the blank. An air-tight foil is arranged over the arrangement. The air-tight foil is forced towards the blank. The support is lowered until the blank is shaped over the tool. The support is stopped and/or removed. The device includes a tool including a top surface and side surface for shaping at least one blank of composite material into an article having a predetermined profile; and a air-tight foil. The device further includes at least one support arranged to be in supporting contact with the underside of the protruding part of the blank.

Abstract: A mold and a process for preparing a customized hot pour product formed of a hot pour material. The process comprises the steps of providing a mold having a top part with a pour space and a base part, applying hot pour material into the mold through the pour space and allowing the hot pour material to cool, removing the top part of the mold to provide a first exposed surface, and releasing the base part to provide a second exposed surface. The mold may be customized to include inserts, removable members, projections, recesses, and combinations thereof in the base part and/or top part, thereby providing for a hot pour product with one or more exposed surfaces that are embossed, debossed, or both.

Abstract: The present invention is a process for producing molded parts from a polymeric powder or metallic powder, wherein the molded part has a separation or a void. The separation or void is formed by inserting a separator or void-forming material into the die cavity before, during or after filling the die cavity with the powdered molding material that is to form the pressed part. After the pressed part is formed the separator or void-forming material is removed to provide the separation or void.

Abstract: A membrane is provided, comprising a first membrane layer having a first side and a second side. The first membrane layer defines a plurality of holes extending along a first axis between the first side and the second side. Each hole is defined by the first membrane layer as a complex three-dimensional shape, and each hole has a diameter of less than about 10 micrometers. The membrane is fabricated by dispersing a liquid polymeric material onto a patterned master template, hardening the polymeric material, and removing it from the master template. The membrane includes through holes which correspond to the structures of the patterned master template in size, cross-sectional and three dimensional shape, orientation, and the like.

Abstract: An apparatus configured to form masonry siding products is provided. The apparatus includes a mold having a mold bottom and a plurality of mold walls defining a mold cavity. A mold carrier is configured to support the mold bottom and the mold walls. The mold carrier has a first member that extends upwardly from a base member and a second member that extends upwardly from the base member. The first member forms an internal first angle of about 90° with the base member. The second member forms an internal second angle in a range of from about 100° to about 110° with the base member. The internal first angle formed by the first member and the base member and the internal second angle formed by the second member and the base member are configured to allow for easy removal of the mold from the mold carrier.

Abstract: A pressing bag comprising silicone rubber sheets and uncured silicone members for covering a prepreg placed on a molding die to cure the prepreg in an evacuated state, the pressing bag being integrally molded in a shape in agreement with the molding die.

Abstract: A method for structurally reinforcing a part is disclosed. The method comprising forming a part into a desired shape; placing the part on a holding fixture; introducing a substrate lay-up of a reinforcing material onto at least a portion of the part; placing a flexible sheet impermeable to a resin of the reinforcing material over a portion of the part having the substrate lay-up of said reinforcing material placed on the part, wherein the flexible sheet includes at least one injection port; evacuating all air and vapor from a pocket between the flexible sheet and the part; introducing the resin of the reinforcing material into the pocket through the at least one injection port; allowing the substrate and the resin of the reinforcing material to cure at least partially; and, removing the flexible sheet from the part.

Abstract: A man-made, molded article is provided. The article includes a profile including a planar wall, and an adjacent integral molded depression having a contoured wall extending downwardly from the planar wall. The contoured wall includes a bead portion, a cove portion, and a ledge between the bead and cove portions. The articles are stackable, one above another for transport, in a nestable relationship in which multiple contact zones are present between the contoured walls of an adjacently stacked pair of the molded articles. The contact zones include an arcuately extending contact interface zone between the bead exterior and interior surfaces. The depression has a substantially uniform thickness varying by no more than about +1 percent to about ?11 percent in relation to a thickness of the planar wall. Related methods and assemblies are also provided.

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: In the sector relating to the technology of compaction by means of vacuum vibro-compression for manufacturing slabs or blocks, the organic binder resin consists of an aqueous dispersion of acrylic prepolymer in water and a filler part consists of a hydraulic binder in an amount sufficient to fix wholly or partly the water present in the initial mix; after the vibro-compression step the rough-formed article is subjected to a hardening and curing step in conditions such as to prevent the evaporation of the mix water and subsequently to a heating step so as to obtain crosslinking of the acrylic polymer. If the acrylic binder alone is used, an article with a high degree of porosity is obtained.

Abstract: A process is provided for bending a board in synthetic material filled with more than 20% by weight of alumina trihydrate in a methyl methacrylate matrix: a section of the board is heated so that it can be bent; the section to be bent is bent while holding the convex upper surface of the board such that it does not become elongated. Also provided are a device for implementing such a process, and a bent board obtained by such a process.

Abstract: A casted concrete stone having opposed parallel surfaces formed in a mold and wherein the opposed parallel surfaces have a molded textured surface. The concrete stone is fabricated by a dry-cast concrete mold wherein a profiling plate is provided with mold bottom wall formations each having a textured outer surface. A bond release film or spray or permanent coating is provided on the textured outer surface of the mold bottom wall formations. Mold forming side walls are disposed about the mold bottom wall formations. After the mold is filled with a dry-cast concrete mixture a top plate, having mold top wall formations, is disposed over the mold forming side walls with the mold top wall formations disposed inside respective ones of the molds to close the molds. Pressure and vibration is applied to compact the dry-cast concrete whereby to form a dry-cast concrete stone with opposed molded textured surfaces.

Abstract: A suction roller (65) is used as a drive roller for feeding a film in a solution casting method. The suction roller (65) has a surface (65a) on which a plurality of circular suction holes (91) is formed. The suction hole (91) has a diameter of 4 mm and a chamfered edge. The width of chamfer is 10% in ratio to the diameter of the hole. The surface (65a) is hardened by chrome plating so as to have a hardness of 900 in Vicars hardness. A roller temperature controller (100) is provided near the suction roller (65) to control the surface temperature of the roller by the air supply. The surface temperature of the suction roller (65) is about 10° C. higher than temperature of the film (61)immediately before contacting to the suction roller (65).

Abstract: The invention relates to a process or a device for the production of a three-dimensional object by layer-wise solidification of a photo-polymerizable resin by means of a planar or essentially planar construction/reference plane, at which the photo-polymerizable resin contained in the liquid material is to be hardened by electromagnetic irradiation, and wherein the material application for the subsequent layer automatically results from the separation of the last hardened layer from the construction/-reference plane, whereby the construction/reference plane is formed by an elastic film. The film is fixed in a frame, and the height position of the frame with the film is adjusted in a basin containing the liquid material such that the pressure of the liquid material compensates the sagging of the film (formation of a negative meniscus), and that the lower side of the film is permanently in contact with the material during the whole construction process.

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: A system and method for insulating an outer surface of a fluid conduit is provided. A portion of the circumference of the outer surface of a conduit is surrounded in a film, thereby forming a generally annular pocket between the outer surface of the conduit and the inner surface of the film. Insulation is deposited into this pocket between the outer surface of the conduit and an inner surface of the film, molded to a substantially uniform radial thickness, and cured to form a cast molded conduit.

Abstract: A method for forming an electronic device provides a casting master having a casting surface, and deposits a substrate material onto the casting surface to form a flexible substrate sheet of predetermined thickness, wherein the flexible substrate sheet has a circuit-side surface that is formed against the casting surface. The flexible substrate sheet is released from the master and secured against a carrier, with the circuit-side surface facing outward. An electronic device is then formed on the circuit-side surface.

Abstract: Thermoformed PLA stereocomplex parts are made using a PLA stereocomplex composition having a highest crystallization melting temperature from 200 to 215° C. The stereocomplex composition preferably has less than 5 J/g of lower melting (160 to 190° C.) crystallites. The stereocomplex can be pre-annealed in various ways to reduce thermoforming cycle times. The stereocomplex forms parts with low haze and good thermal resistance, at reasonable cycle times.

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: 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: The invention relates to a method for producing an adhesive fastening element made of plastic, comprising a support part (10) from which project a plurality of stem parts (12) and where a head part (14) is arranged at each of the ends of said stem parts, the ends opposing the support part (10). According to the invention, a moulding tool (16) is used for moulding the stem parts (12), which extends between the support part (10) and the head parts (14) and is removed in a de-moulding process once the stem parts (12) have been moulded. The invention is characterized in that the head parts (14) are formed without the use of moulding tools due to the surface tension of the used plastic material and, consequently, there is no need for a specific moulding tool for forming the head parts, as is characteristic of the prior art.

Abstract: A system for distributing a substance includes a chamber configured to accommodate a mold surface and an inlet port in the chamber. The substance is introduced into the chamber through the inlet port. Flexible tubing is coupled between the inlet port and a reservoir containing the substance. A pump is used to compress a portion of the flexible tubing to move the substance through the tubing and inject the substance into the chamber.

Abstract: A method of continuously feeding film pieces for the molding process includes a film preparation task, a film drawing task, a film cutting task and a film feeding task. The film preparation task includes preparing a roll of film and drawing the film out and fixing a head end thereof at a first position. The film drawing task includes holding the film and drawing the film along a film feeding direction to have the head end to a second position. The film cutting task includes cutting the film off to have a film piece,. The film feeding task includes holding the film piece and moving the film piece to a third position. The film preparation task, the film drawing task and film cutting task are repeated in sequence for continuously feeding film pieces for the molding process.

Abstract: Extruding radiused plastic articles with an extruding machine terminating in die defining a path of travel between upstream and downstream ends. The die has an outlet opening extending longitudinally in the direction of the path of travel, the opening oriented so a polymeric material is extruded therefrom in a direction approximately perpendicular to the path of travel through the die. Oppositely rotating rollers of tapered diameters are disposed side by side to receive the extrudate therebetween, the rollers arranged so their longitudinal axes intersect and their smaller diameters are oriented towards the downstream end of the die. Extrudate passing through the opening is characterized by a higher flow rate proximate the upstream end thereof to thereby form a radiused extrusion. The rollers draw the extrudate from the die outlet opening without significantly altering the radiused shape of the fluid plastic material.

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 system and method is disclosed for using a pre-formed film in a transfer molding process of the type that uses a transfer mold to encapsulate portions of an integrated circuit with a molding compound. A film of compliant material is pre-formed to conform the shape of the film to a mold cavity surface of the transfer mold. The pre-formed film is then placed adjacent to the surfaces of the mold cavity of the transfer mold. The mold cavity is filled with molding compound and the integrated circuit is encapsulated. The pre-formation of the film allows materials to be used that are not suitable for use with prior art methods.

Abstract: The disclosure is directed to a process for producing resin infused composite parts having improved structural performance and improved surface appearance. The process comprises the steps of positioning a dry composite preform on a forming tool component, arranging resin exit lines in close proximity to the perform, placing a permeable release material on the perform, and placing a first piece of flow media over the release material. The process further comprises the steps of wrapping a resin distribution tube with a second piece of flow media, placing a vacuum bag layer over the forming tool component, preform, release material, first and second pieces of flow media and resin distribution tube, such that the resin distribution tube is retained in a pleat formed in the vacuum bag layer and such that a bagged preform is formed, and positioning the resin distribution tube above the bagged preform.

Abstract: A microstructure roller formed of a cylinder and a resin pattern layer is disclosed. The microstructure roller is made by: providing a cylinder having a groove extending around the periphery, and then adhering a flexible mold plate to the periphery of the cylinder to have a cavity be defined in between the groove of the cylinder and a patterned face of microstructure patterns of the flexible mold plate, and then filling a resin in the cavity, and the curing the resin, and then removing the flexible mold plate from the cylinder.

Abstract: A safety seat comprising a unitary molded shell having a “bucket-seat” shape and a safety restraint system integral to the shell. The molded unitary shell has a bottom portion and a back portion. The shell comprises an inner layer and an outer layer made of a carbon fiber laminate with a core situated between the inner and outer layers. The core comprises aluminum sheeting having a honeycomb-like cross-section. A plurality of attachment plates are selectively located within the shell and disposed between the inner and outer layers. The safety restraint system is fastened to corresponding attachment plates. Support plates located on a non-seating surface of the shell are mated with selected attachment plates. A headrest is selectively attached to the safety seat. The safety seat is secured to structural members within a vehicle by mounting brackets. A method for making the shell and assembling the safety seat are disclosed.

Abstract: A mulch mat made of recyclable material is provided having a mulch-appearing surface made of recycled material such as rubber and another surface made of a plant inhibiting fabric. The fabric extends beyond the mulch-appearing surface on at least one edge of the mat to provide an area upon which another of the mats may be positioned to prevent weed, grass and other plants from growing between the mats. In addition, the mulch mat may include fertilizer to nourish nearby trees, bushes and the like.