Abstract: Form inserts are provided that can include a flexible sheet having multiple ribs extending from at least one surface of the sheet. Methods for curing material are provided that can include expanding a sheet over an interior portion of one form defining a perimeter of material to be cured. The sheet can include ribs extending from a surface of the sheet to within the perimeter. Column form inserts are also provided that can include a plurality of circular ribs defining a perimeter of a column form. Methods of producing a form insert comprising providing a sheet of flexible material and adhering a flexible mesh to the sheet, the flexible mesh forming ribs extending from at least one surface of the sheet, are also provided.

Abstract: A device for making panels with three-dimensional curvature from a sheet material, includes a forming impression (5) defined by a membrane (6) including an elastically stretchable skin (11), preferably in combination with a skeleton formed by a grid pattern of flexurally elastic battens (10) which are mobile in longitudinal translation relative to the skin, and a set of elements for selectively deforming the impression acting on the battens (10) of the membrane to impart thereto an adaptable three-dimensional curvature. The invention is particularly useful for making sails.

Abstract: An apparatus and a method for the separation of a material layer (4) hardened on a flat plane (2) serving as a reference by means of a flexible, elastic separating layer (1) arranged between plane and material layer and designed in the form of a film or a gel-like material, are provided.

Abstract: A method for forming composite articles from a thermoplastic preform using a bladder molding system. In one aspect, the method comprises suspending the preform above a tensioned release layer in an indexed manner prior to heating and forming the preform. In another aspect, the method comprises cold loading the preform into the bladder molding system about the mold cavity and subsequently heating and forming the preform without further handling the preform.

Abstract: A resin infusion mold tool system for use in a vacuum assisted resin transfer molding process with a subsequent pressure bleed step. The mold tool system includes a mold assembly having an outer mold line tool connected to resin supply lines and supplying resin to the preform. A plurality of inner mold line tools form a hard interface with the inner mold line of the fiber preform and are held to within tight tolerances by an external locating fixture. Excess resin is drawn out of the fiber preform using a vacuum bag connected to vacuum lines and disposed over the inner mold line tools but not between the tools and the fiber preform. The mold assembly is placed in an autoclave, the resin supply lines are detached and the autoclave pressurized to bleed additional resin out of the preform to raise the fiber volume of the composite structure.

Abstract: Process for molding and vulcanizing a tire, in which a tire blank is placed in a curing press comprising a mold intended to form the outer shape of the tire, and a pressing member for transmitting the molding pressure and the heat needed to vulcanize the internal portion of the tire blank. A removable elastic membrane, which includes perforations passing completely therethrough, is interposed, during the molding and the vulcanizing step, between the inner surface of the tire and the pressing member, so as to form, by the constituent material of the internal wall of the tire flowing into the perforations, noise-attenuating protuberances distributed over the internal surface of the tire.

Abstract: The present disclosure provides a method for producing detectable warnings (16) on substrate surfaces (14), which includes providing a mat (30) with a top surface (38) and a bottom surface (36) and a pattern of mat through holes (34) extending through the mat (30). The through holes (34) comprise a lower portion (44) defining a lower mat opening (33) and an upper portion (32) defining an upper mat opening (35), wherein the upper mat opening (35) is larger in transverse dimension than the lower mat opening (33). The method further includes placing the mat (30) on a substrate surface (14), wherein the bottom surface (36) of the mat (30) is adjacent the substrate surface (14), and injecting into the mat through holes (34) a viscous substance (40) having the ability to cure into a solid. The method further includes removing the mat (30) at the appropriate time to form raised detectable warnings (16) on the substrate surface (14).

Abstract: The invention is directed to a process for elimination of deformations on resin infused composite parts in which the resin distribution tube used in a resin vacuum infusion process is positioned above the surface of a preform and is not in contact with the preform. Flow media indirectly connects the resin distribution tube to the preform which allows for free movement of resin without direct contact of the resin distribution tube to the perform, and thus, this eliminates deformations that are caused by direct contact of the resin distribution tube to the preform.

Abstract: A method and kit for forming a definitive prosthetic socket directly on a residuum without the use of a water hardenable material. A chamber surrounding a web of braided fibers is created on the residuum via the use of inner and outer protective sheaths. A hardenable or curable material for forming the prosthetic socket is injected into the chamber around the web. Pressure is applied around the chamber to form the definitive prosthetic socket.

Abstract: The objective of the invention is to prevent electrostatic destruction of semiconductor chips during resin molding. With the semiconductor device manufacturing method, a substrate 400 that includes on the surface multiple semiconductor chips 410 and liquid resin 434 supplied to multiple semiconductor devices is supported by an electrically insulated lower die 200. An upper die 110 in which multiple shape-forming parts (cavities) 112 are formed is pressed against lower die 200 through the medium of a polymer release film 300, and liquid resin 434 on the substrate is molded.

Abstract: A semiconductor component includes a leadframe, a die, upper and lower body segments encapsulating the die, and dummy segments on the leadframe. The dummy segments are configured to vent trapped air in a molding compound during molding of the body segments, such that corners of the body segments do not include the trapped air.

Abstract: A method and apparatus is provided for molding a semiconductor device in a mold including two mold halves. One mold half includes a compressible sealing mechanism constructed and configured to exert a sealing pressure between a surface of the mold half and a surface of a semiconductor device located in the mold. A compliant tape is positionable onto the mold half comprising the sealing mechanism between the semiconductor device and the sealing mechanism for molding of the semiconductor device.

Abstract: For manufacturing a moulded article comprising at least an elastomeric polyurethane skin (9) and optionally a structural backing layer (10) and an intermediate foam layer (12) a mould is used having at least a first mould part (1) comprising at least two mutually movable mould sections (2-4). The skin (9) is moulded with its front against a surface (7) of the first mould part (1) by applying at least one reactive polyurethane mixture to this mould surface. In order to prevent the seam between the mutually movable mould sections (2-4) of the first mould part to leave traces on the front of the moulded skin (9), the first mould part (1) further comprises a removable, flexible liner (6) which is positioned onto these mould sections to cover at least partially the seam therebetween.

Abstract: This invention is a method for the precise placement of indicia with high resolution into the wall of a hollow-form, molded plastisol part. The method includes the steps of preparing a plastisol graphic transfer by casting a base layer of plastisol onto a carrier sheet, printing indicia with pigmented plastisols onto the base layer of plastisol to form a graphic transfer, and over printing the graphic transfer with a body layer of plastisol. After each layer of plastisol is deposit, the layer cured by heating before depositing the next layer and the transfer is heated to cure the final, body layer.

Abstract: The method of transferring a coating onto articles having skew surfaces comprises the steps of applying a coating on the articles, which coating is carried by a transfer support that has a pyrolysis temperature lower than a melting temperature of the coating, the coating itself having a sealing temperature lower than the pyrolysis temperature of the transfer support, and then of subjecting articles coated in this way to the melting temperature of the coating.

Abstract: A mold assembly for producing a molded object from resin. The assembly includes a cavity configured to be filled with resin to form at least one surface of the molded object into a predetermined shape with at least one transfer surface of the cavity. A molding insertion member is arranged to form another surface of the molded object, and a holding insertion piece is configured to hold the molding insertion member. The holding insertion piece includes a communication path that places a surface of the molding insertion member at a side opposite to the cavity in fluid communication with the exterior of the mold assembly and guides air from the exterior of the mold assembly toward the surface of the molding insertion member.

Abstract: A method of manufacturing a large double-sided curved Fresnel lens. The method includes a machining step (A) of performing ultra-precise three-dimensional machining on an upper mold and a lower mold to each have an upper transfer surface and a lower transfer surface engaging an upper surface and a lower surface of a thermoplastic resin plate, respectively. Further, the method includes a hot press molding step (B) of pressing the thermoplastic resin plate between the upper and lower molds by a predetermined pressure with the resin plate being held at a temperature higher than a softening temperature thereof and lower than a melting temperature thereof so that the thermoplastic resin plate is curved, and both lens surfaces for the double-sided Fresnel lens are respectively transferred to an upper surface and a lower surface of the thermoplastic resin plate.

Abstract: This invention relates to a method for manufacturing a large FRP member including: disposing a preform containing a reinforcing fiber on a surface of a molding die; covering a molding portion with a bagging material or a mold and providing a suction port and a resin injection port for sealing; evacuating the molding portion through the suction port; heating the molding portion; injecting a thermosetting resin from the resin injection port for impregnating the reinforcing fiber with the resin while a temperature Tm of the molding die and a temperature Tv of the bagging material or the mold are both set to room temperature or more, and a difference ?T in temperature between the Tm and the Tv is set to 10° C. or less; and curing the resin by maintaining the molding portion at a predetermined temperature Tpc which is equal to or more than room temperature.

Abstract: A unitary polymer substrate having a plurality of microfibers projecting from a surface is provided. The presence of the microfibers greatly increases the surface area and can impart a cloth-like feel to the surface. The projecting microfibers may have a variety of forms, including frayed-end microfibers, tapered microfibers, microfibers having an expanded cross-sectional shape, and microfibers having a very high aspect ratio. A number of methods of producing unitary polymer structures with a plurality of projecting microfibers are also provided.

Abstract: An apparatus for forming panels from moldable material comprising: a material storage and feeding container for placing moldable material on a sheet of peel ply material on top of a conveyor. The conveyor has a roughened surface for gripping the sheet of peel ply material. The moldable material is leveled by a sizing plate which also places a second sheet of peel ply material over the moldable material to form a web. The web is compressed in a compression zone and is stabilized in thickness to form panels of compressed, dimensionally stabilized material as it is moved by the conveyor. Also disclosed is a method for making such panels from moldable material.

Abstract: A process for the production by a moulding process of a micro-cellular or non-cellular elastomeric polyurethane skin layer or, more generally, to a process for the production of a composite comprising a first layer shaped part, which is made by a moulding process from a polyurethane reaction mixture, and a second layer shaped part which is adhered to the first part to form the composite. In order to avoid the use of release agents on the back side of the first layer shaped part, and thus the negative effect on the adhesion of the second layer shaped part, and the penetration of reaction mixture on this back side between the slides (9–10) of the mould, the mould surface (4) is covered on the back side of the moulding with a removable flexible covering (12), with a removable rigid pre-shaped covering or with a permanent non-stick coating layer.

Abstract: This invention refers to a method and a device for use in connection with the fabrication of multilayer products (8) such as composites and bonded multilayer sheet products, ect. by means of the so-called “bagging technique,” to increase the compressive pressure (P) on the product being created beyond normal atmospheric pressure. In the bagging technique, which is used to join a plurality of different material layers with one another to form a unit via polymeric binder layers, atmospheric pressure is normally used to press the various objects together in that they are enclosed in a depressurized gas-impervious bag (9, 21) while the various layers are joined to form a unified product.

Abstract: A process for fabricating a faceplate for a flat-panel display such as a field emission cathode type display is disclosed, the faceplate having integral spacer support structures. Also disclosed is a product made by the aforesaid process.

Abstract: A contoured wall and method is disclosed for creating the contour and appearance of a wall formed from individual assembled units such as stones. The wall is formed from a plurality of mating form liners each having a reciprocal contoured surface to that of the desired stone wall. The wall is formed from hardenable construction material such as concrete poured between two mold members with the form liners attached to at least one of the mold members. Each of the form liners has a lateral relief mold face adapted to provide a molded surface having the contour of a stone wall. Each lateral relief mold face of the form liners has a latticework non-linear mortar-forming interlocking portion surrounding stone-forming recessed portions. The form liners are positionable in a plurality of arrangements wherein the interlocking portions and recessed portions along the mating edge of each form liner mate along mating edge of the adjacent form liner to form a continuous lateral relief mold face.

Abstract: A method and system (10) having a flowable pressure pad (22) for consolidating an uncured laminate sheet (14) during a cure cycle is provided. The system (10) includes an autoclave machine (12) for utilizing a pinmat (20) for to perforate and consolidate the sheet (14). This pinmat (20) has a mat portion (28) and a plurality of pins (26) extending from the mat portion (28). These pins (26) are intended to penetrate the uncured laminate sheet (14) during a perforation cycle that occurs prior to the cure cycle. During the cure cycle, the autoclave machine (12) applies a predetermined amount of and pressure heat to the pressure pad (22) for a predetermined amount of time so as to cause the pressure pad (22) to flow around the protruding pins (26). This feature allows the pressure pad (22) to transfer a substantial portion of the applied pressure to the uncured laminate sheet (14) so as to improve consolidation of the sheet (14).

Abstract: A system (10) is provided for perforating and consolidating an uncured laminate sheet (14) at a substantially low pressure in one cycle of operation. The system (10) includes a pinmat (20) that is coupled to a tool base (24). This pinmat (20) is comprised of a mat portion (28) and a plurality of pins (26) extending from the mat portion (28). These pins (26) are intended to displace discontinuous fibers (32) within the laminate sheet (14) so as to perforate the laminate sheet (14). Furthermore, the mat portion (28) has one or more ventilation holes (58) integrally formed therein for allowing gas adjacent to the pins (26) to be withdrawn therefrom so as to improve the consolidation of the laminate sheet (14). The system (10) also includes a positive pressure source (12) that is coupled to the laminate sheet (14) for forcing the laminate sheet (14) onto the pinmat (20).

Abstract: The invention relates to the formation of a smooth attractive surface on a composite molded article. More particularly, the invention relates to combining materials in a mold to result in a composite article having a finished surface. The invention relates to a method having improved efficiency and reduced emissions of hazardous air pollutants used in making composite molded articles comprising a reinforced thermosetting material having a thermoplastic exterior layer.

Abstract: The invention relates to the formation of a smooth attractive surface on a composite molded article. More particularly, the invention relates to combining materials in a mold to result in a composite article having a finished surface. The invention relates to a method having improved efficiency and reduced emissions of hazardous air pollutants used in making composite molded articles comprising a reinforced thermosetting material having a thermoplastic exterior layer.

Abstract: The invention relates to the formation of a smooth attractive surface on a composite molded article. More particularly, the invention relates to combining materials in a mold to result in a composite article having a finished surface. The invention relates to a method having improved efficiency and reduced emissions of hazardous air pollutants used in making composite molded articles comprising a reinforced thermosetting material having a thermoplastic exterior layer.

Abstract: The invention relates to the formation of a smooth attractive surface on a composite molded article. More particularly, the invention relates to combining materials in a mold to result in a composite article having a finished surface. The invention relates to a method having improved efficiency and reduced emissions of hazardous air pollutants used in making composite molded articles comprising a reinforced thermosetting material having a thermoplastic exterior layer.

Abstract: A method of forming sculptured designs onto a substrate using a hand tool includes a container that can contain compound that is suitable for placing sculptured designs onto a substrate such as a ceiling or a wall, and an applicator that can move into and out of the container. A pattern on the applicator unit includes pattern elements that are arranged in a selected pattern and have cavities defined therebetween. The cavities are sized to temporarily accommodate compound that is used to define the sculptured design on the substrate and are arranged in a pattern such that the compound will define the desired pattern when the applicator is pressed against the substrate.

Abstract: A process for the production of a panel (7) of composite material with stiffening strips (3), in which a mold (1) is draped with at least one first ply (2) of fibers pre-impregnated with resin, there is emplaced at desired positions on said ply (2) at least one stiffening strip (3), the stiffening strip (3) as well as at least a portion of the remaining surface of the first ply (2) is covered with at least one second ply (4) of fibers pre-impregnated with resin, then a bladder (6) is placed to cover the above elements, the assembly is then placed under vacuum and then in an autoclave to polymerize the resin. Before emplacement of the stiffening strip (3) and/or of the second ply (4), there is interposed at least one layer (5) of a non-adherent material between at least one portion of the surface of the stiffening strip (3) and one and/or the other of the plies (2, 4).

Abstract: The resin molding machine and a method of resin molding of the present invention are capable of securely and efficiently mold a work piece, on which a plurality of elements are arranged. The resin molding machine comprises: a lower die on which a work piece to be molded is set; an upper die clamping the work piece with the lower die; a clamper being provided to the upper die, the clamper enclosing a resin molding space of the upper die, the clamper being capable of vertically moving in the upper die and always biased downward, wherein a lower end of the clamper is downwardly projected from a resin molding face of the upper die when the lower die and upper die are opened; and a release film feeding mechanism feeding release film, which is easily peelable from the upper die and resin for molding, so as to cover the rein molding space.

Abstract: Processes and systems to reduce sticking of graphite materials and particularly resin impregnated graphite materials to forming tools, such as an embossing roller, during a process of manufacturing articles from the graphite materials. In one embodiment, an aerosol spray non-stick material is intermittently sprayed upon the embossing rollers. In a second embodiment, one or more sheets of thin flexible solid non-stick material, such as polyethylene, are sandwiched between the graphite material and the embossing rollers. The system is particularly useful for manufacturing material useful in producing components of fuel cells.

Abstract: A method for forming an outsole of an article of footwear includes the steps of placing an upper and an insert in a mold cavity, filling the mold cavity and a gap between the upper and the insert with a foamable material, and closing the mold cavity and subjecting the foamable material to expansion and molding so as to form the outsole with the insert inlaid therein.

Abstract: An adaptation device and method for molding a dental material to a die in the preparation of a dental coping with the die having the shape of a tooth to be restored and with said dental material placed over said die. The adaptation device includes a base for placement of the die, a cover mounted on the base over the die to form an enclosed chamber, an inlet opening extending through the cover into communication with the chamber, a source of a gaseous fluid connected to the inlet opening for pressurizing the chamber, an outlet opening extending through the base in proximity to said die and diaphragm means removably positioned in the chamber to surround the die and to isolate the outlet opening from the chamber such that upon pressurizing the chamber the diaphragm is caused to collapse about the die and to apply a uniform pressure over the dental material for adapting the dental material to the die.

Abstract: Apparatus for moulding composite materials comprises a frame (8) holding the margins of a pair of elastomeric membranes (4, 5) substantially in a plane in facing relationship. The frame (8) is secured within a moulding chamber formed by upper and lower sections (1, 2) respectively to divide the moulding chamber into a mould side MS which contains a mould form (9) and an opposite side OS. A jack diagrammatically illustrated at (13) is provided for effecting relative movement between the frame and the mould form (9) in the direction generally perpendicular to the plane of the frame. A resin introduction port (19) is provided for introducing resin between the membranes (4, 5) at a central region Ducting (11) is provided for aspirating the inter-membrane space, and inlet ducts OSI and MSI and outlet ducts OS2 and MS2 are provided for respectively pressurising and aspirating the mould opposite side OS and the mould side MS of the moulding chamber. To be accompanied, when published, by FIG. 1 of the drawings.

Abstract: According to one embodiment of the invention, a co-cured resin transfer molding manufacturing method includes providing a tool having one or more tooling details and disposing one or more preforms proximate the one or more tooling details. The one or more preforms are either dry or binderized. The method further includes disposing a high permeability medium outwardly from the one or more tooling details, disposing a prepreg skin panel outwardly from the high permeability medium, disposing the one or more tooling details and the prepreg skin panel within the tool, injecting a resin into the one or more preforms, and curing the one or more preforms and the prepreg skin panel.

Abstract: A method for manufacturing rubber plate having colored patterns thereon includes step 1: to prepare a heat transfer decal having a colored pattern thereon, the color pattern including a plurality of slits located at corners of the colored pattern; step 2: to prepare a male mold and a rubber plate put on the male mold, the decal put on the rubber plate; step 3: to prepare a female mold having a recess defined therein, and step 4: to press the decal on the rubber plate between the male mold and the female mold at a high temperature. The pattern on the decal is printed on the rubber plate.

Abstract: A method and apparatus for molding composite articles can include a pair of opposed hollow mold sections having first and second molding membranes which define a mold plenum therebetween. Each mold section can be filled with a substantially noncompressible, thermally conductive fluid. The temperature of the mold plenum can be controlled by regulating the temperature of the thermally conductive fluid. Sensing of various parameters during the injection and curing processes of the molding fluid, for example pressure, flowrate, temperature and filling of the plenum can be used to optimize the molding process.

Abstract: A molded wood composite article man-made from wood fibers or wood particles on at least an upper, molded surface of the article, and a method of manufacturing the article to include a relatively uniform density, detailed design contours and textured aesthetics on one or more molded depression-interior inclined surfaces, while preventing embrittlement, softness and blistering of the article along the depression-interior inclined surfaces. These attributes are achieved by molding one or more depressions into an initially planar layer of cellulosic material, wherein the molded depressions have a length to depth ratio in the range of about 5.0 to about 8.5, and have one or more inclined walls that have upper surfaces, along essentially an entire inclined span, that include detailed design contours, including adjacent curved and planar portions, e.g., bead and cove.

Abstract: A process for fabricating a face plate for a flat panel display such as a field emission cathode type display is disclosed, the face plate having integral spacer support structures. Also disclosed is a product made by the aforesaid process.

Abstract: There is disclosed a method for simulating a mould-imparted texture including applying a textured skin to a moulding from a pre-textured mould.

Abstract: A split-mold, which is used for manufacturing semiconductor devices by resin-encapsulating a substrate on which a plurality of semiconductor chips are formed, includes a first mold and a second mold. The second mold has a pressing surface that is provided with a mold release sheet. The second mold has a mold-release-sheet mechanism holding a mold release sheet outside the pressing surface of the second mold and applying tension to the mold release sheet.

Abstract: In accordance with the present invention, there is provided a process for forming a fiber-reinforced resin structure against a mold surface by vacuum bag forming. The process includes grooving the mold surface to form resin distribution conduits therein. A fiber-reinforced ply is distributed adjacent the mold surface. A flexible covering is placed over the fiber-reinforced ply and the mold surface to form a chamber therebetween. The chamber is evacuated. Resin is dispensed into the evacuated chamber such that the resin enters the resin distribution conduits and is thereby distributed about the ply.

Abstract: A reusable vacuum bag apparatus for use in a compaction operation by which composite parts are formed. The apparatus includes a flexible, inflatable support structure which is secured to a reusable flexible mat vacuum bag. When inflated, the support structure maintains the vacuum bag in the orientation it needs to assume when placed on a forming tool associated with a compaction apparatus. The support structure is formed by a plurality of intercoupled linear and curving tubing segments which form a grid-like support structure. The support structure is shaped in accordance with the configuration and contours of the reusable vacuum bag portion, which is in turn shaped in accordance with a forming tool. The support structure can be de-inflated, which allows the vacuum bag secured thereto to be stored in a compact arrangement when not in use.

Abstract: A diaphragm chamber molding apparatus and method including a chamber for containing a mold surface therein; a bottom flexible diaphragm placed over and sealable with respect to the top of the chamber; a top flexible diaphragm placed over and sealable with respect to the bottom diaphragm for containing a lay-up between the top and bottom diaphragms; means for evacuating the area between the top and bottom diaphragms; and means for drawing the top and bottom diaphragms and the lay-up therebetween down over a mold surface located in the chamber to form the lay-up.

Abstract: An apparatus and a process for the compression and/or injection in-mold lamination of a decorative material (1) and for the complete bordering of at least part of the edge (2) of this decorative material with a backing material (3) are proposed. The apparatus comprises at least two mold parts—forming a cavity (4). A first mold part (5) comprises pressing means (7) and a second mold part (6) comprises holding means (8) for holding a decorative material (1), placed into the cavity (4, 4′), at a distance from a surface (9) of the cavity formed by the second mold part (6), these holding means (8) being arranged raised with respect to this surface (9), entirely within the cavity (4, 4′) and immovably with respect to the surface (9) of the latter.

Abstract: A method of manufacturing a resin impregnated article includes the steps of providing a mold onto which a reinforcing material is placed, sealing the reinforcing material with an impervious sheet and regulating the pressure on the material and temperature of the material and resin by placing a fluid in contact with the impervious sheet and regulating the pressure and temperature of the fluid.

Abstract: Process for moulding a make-up composition in a mould comprising a concave moulding surface forming the base of the mould and a bottom forming the upper component of the mould and closing off the space bounded by the said moulding surface, the composition being cast in the said mould in fluid form and subsequently solidifying to form a demouldable solid product capable of being packaged, in which the said composition is cast in a mould (1) whose bottom consists at least partly of a sheet (2) of open-cell plastic foam, so as partly to impregnate the said foam sheet (2) with the said composition and in which, after solidifying of the said composition, a moulded product consisting of the solidified composition and of the foam sheet which is bonded to it and which forms its support, is demoulded by removing the moulding surface (1).