Abstract: A component made of at least one thermoformable material, having a first layer made of a first material, a second layer made of a second material, and a third layer made of the first material. The three layers form a sheet, which is formed to various shapes, depending upon the part that is to be created. The sheet may be formed to produce the bumper of an automobile, a door panel for an automobile, a flotation device, such as a pontoon for a pontoon boat, or the like. The first and third layers are SMC, and the second layer, or “core,” is disposed between the first and third layers, allowing the strength of the first and third layers to be used more efficiently, compared to a sheet having only the first and third layers, and no core.

Abstract: The invention relates to a process for making a medical component such as a medical implant for example a graft or stent-graft, said medical component comprising ultra high molecular weight polyethylene (UHMWPE) fibers, a medical component obtainable by said process as well as uses of said process and medical component.

Abstract: A method of fabricating a composite vessel encompassing rapid manufacturing that is applicable to composite hydrogen and other gas storage tanks, both for high-pressure cylinders, as well as low-pressure conformal tanks. The process of fabrication includes using a liner, of metal or plastic materials, over which a braided or developed preform is wrapped. The dry fiber wrapped liner is placed in a mold and resin injected into the cavity formed between the liner and the mold outer walls. The liner is flooded with heated and/or cooled pressurized fluid thus enabling complete and independent process control from within the liner for both the resin injection and the cure phases. Fiber placement control is determined through combined biaxial and triaxial braid/preform design, and by wrapping at controlled tension onto the supporting liner. Fiber tension control is further enhanced by the methodology of mold loading whereby tensioning forces are enacted during actual load and close.

Abstract: A process is disclosed for forming a three-dimensional structure from a nonwoven web. The web is made of synthetic polymer filaments. The process comprises subjecting the web to a molding force at a temperature between the glass transition temperature and the melting temperature of the polymer. The nonwoven web is constructed so as to allow ample elongation of the constituent filaments. The web is preferentially bonded in selected areas. The filaments are only partially drawn during the spinning process, so as to preserve elongation potential. The three-dimensional structures made by the process can be shaped filters, for example for use in beverage capsules.

Abstract: The present invention relates to a three dimensionally fiber-reinforced riser and to the unitary or single-step methods of making the same. In one embodiment (a cross bow riser for example), the riser has an interior support with opposed side members and a front brace. The front brace has a depression centrally located therein. Two side ribs are also provided for structural support. Two pockets each optionally having a divider wall defining a top and bottom section are provided for receiving respective top and bottom pieces of a split limb, when a split limb is used. The riser can be made of a composite material having fibers aligned there within in the directions of the highest stresses for enhancing the structural strength of the riser. Other bow parts or components can likewise be made via composite material as well.

Abstract: A method of vacuum-assisted RTM includes disposing a resin distribution medium on one surface of a reinforcing-fiber substrate, covering the whole with a bag material, reducing the pressure inside the bag material, and injecting a resin into the resin distribution medium to distribute the resin substantially in in-plane directions and then impregnate the resin into the reinforcing-fiber substrate in the thickness direction.

Abstract: A grinding and cleaning fleece 1, for the machine-based grinding and machine-based cleaning of structured surfaces, consists of a fleece body 10, which includes a processing surface 11 with a plurality of burls 14. A method of manufacturing and use of the cleaning fleece is also disclosed.

Abstract: Described herein is a formation press for manufacturing a three-dimensional fibrous preform. The press includes a compression zone with an amount of an aqueous slurry of fibrous material. At least two orthogonally disposed compression members are for compressing the material in the compression zone. The compression members are in communication with the compression zone for movement relative to it. The compression members are moveable with sufficient inwardly directed force to compress the material so as to form the three-dimensional perform in the compression zone.

Abstract: Polymeric composite stents reinforced with fibers for implantation into a bodily lumen are disclosed.

Abstract: A blade for a hockey stick which can readily absorb impact from the puck, and can allow the user to feel the puck on the blade in contrast to conventional carbon fiber blades. The blade can include a blade member integrally formed of composite material having discontinuous fibers bonded within thermosetting resin. The blade member can have a blade periphery surrounding a central blade region. The central blade region can have a plurality of openings arranged in a pattern to form series of elongate criss crossing ribs that extend between and connect different sides of the blade periphery to each other. The fibers in the blade periphery can be in a generally jumbled orientation, and the fibers in the central blade region can be positioned within the ribs in a manner wherein each rib contains a plurality of fibers that substantially extend in said each rib's elongate direction.

Abstract: A gas turbine engine blade for aircraft which has a 3-dimensional blade surface shape twisted around a center line at an angle of 45 degrees or more and 70 degrees or less, wherein the aforementioned blade is provided with multiple composite material prepregs which contain reinforced fiber and which are integrally molded after being laminated in the thickness direction, and the aforementioned reinforced fiber runs continuously without interruption within each layer of the aforementioned composite material prepregs.

Abstract: A device changes the shape of a die used to compression mold a part. The device includes a sleeve placed between the die and a charge to be molded. The sleeve has an inner face generally conforming to a face of the die, and a outer face for molding a part.

Abstract: A process comprising: placing a preform stack in a cavity of a molding tool; the preform stack comprising a fiber mat, and at least a first veil underlying the fiber mat, and a first resin impregnating at least the fiber mat, and wherein at least a portion of the first resin is cured; injecting a second resin into the cavity of the molding tool and over at least the fiber mat; applying heat and pressure to the preform stack and second resin to cure any uncured portion of the first resin and to cure the second resin to form a composite having a resin layer over the fiber mat as the cosmetic surface.

Abstract: The invention relates to a press felt for use in the press section of a paper machine. Said felt comprises a nonwoven layer lying on one of its surfaces, the surface of said layer being connected and fixed to the felt by a thermoplastic binding material. According to the invention, the surface of the nonwoven layer is smoothed by the application of pressure from a smooth surface during the cooling of said layer surface from a temperature in excess of the melting temperature of the thermoplastic binding material to a temperature below the melting temperature. To manufacture the press felt, an untreated press felt, which contains the nonwoven layer and the thermoplastic binding agent is first produced, the thermoplastic binding agent being distributed in the nonwoven layer in the form of thermoplastic adhesive fibres and/or a thermoplastic adhesive component of bicomponent fibres.

Abstract: A method and apparatus for manufacturing a composite stringer. A composite material and foam are laid up onto a tool in the form of a stringer. The foam has a plurality of structural members within the foam. The plurality of structural members has a number of orientations to resist a number of loads. The composite material, the foam in the form of the stringer, and the plurality of structural members are cured to form the composite stringer.

Abstract: A method of manufacturing a component from a composite-fiber-material semifinished product includes providing a forming support having a contour including at least one section corresponding to a surface of the manufactured component. The semifinished product is placed onto the forming support and the semifinished product is formed such that the semifinished product contacts the forming support. Further, a device form manufacturing component includes the forming support having the contour including at least one section corresponding to the surface of the manufacture component.

Abstract: A flexible preform for producing, by heating and shaping, a component based on natural fibres, the preform being including a core made of a nonwoven of natural fibres, at least one surface of which is bonded to a woven fabric made of natural fibres.

Abstract: A nonwoven, fire retardant, moisture resistant panel and method of construction thereof is provided. The panel includes a bonded nonwoven sheet of bast fibers bonded with polymeric binding fibers. Further, the panel includes a single coating of a dried and cured solution. The dried and cured coating includes a binder, a Ph stabilizer and a single flame retardant.

Abstract: A method for producing a foamed article including a supporting element, a foam layer, and an upholstery cover applied on said foam layer, comprising the steps of forming said upholstery cover by stitching together a plurality of lengths of upholstery cover, positioning the sewn upholstery cover on a convex positioning surface of a positioning member withholding the sewn upholstery cover on said positioning member by means of a first suction system, setting said positioning member with the sewn upholstery cover withheld thereon by suction in a bottom die of a foaming die, deactivating said first suction system and withholding the upholstery cover on a concave positioning surface of said bottom die by means of a second suction system, extracting said positioning member from said bottom die leaving said upholstery cover positioned and withheld by suction on said concave positioning surface, positioning a rigid supporting element on a plunger of said foaming die and closing the plunger on said bottom die so as to

Abstract: A manufacturing process for making short fiber low denier unitized composite fabrics with abrasive features includes steps of depositing an assembly comprising one or more layers of fibrous material and optionally one or more layers of non-fibrous material, at least one of the outer layers containing a multicompartment synthetic fiber, and activating at least one component of the multicomponent fiber to impart an abrasive attribute to the outer surface.

Abstract: A carrier mold having prongs that produces shaped tampons is provided. A carrier mold comprising an outer surface, an inner surface, a first end, a second end opposite the first end, a body, and two or more prongs, each prong having a proximal base and a distal end; wherein at least one prong is in partial contact with at least one other prong; wherein the inner surface defines an inner cavity for producing a shaped tampon; wherein the inner cavity is structured to define or mirror the desired shape of the shaped tampon; and wherein the shaped tampon has a length and comprises various perimeters along its length. A method of forming a shaped tampon using the carrier mold is also provided.

Abstract: The present invention relates to a wood composite panel having a major planar portion, at least one panel portion, and an inwardly extending contoured portion surrounding the panel portion and interconnecting the major planar portion and the panel portion. The contoured portion defines an inter-relationship between a vector angle and a deep draw depth that achieve a satisfactory stretch factor. The present invention also relates to a door having the disclosed wood composite door facings, and methods of forming the facing and door.

Abstract: A method for forming a suspension element for an acoustic driver. The method includes placing an unimpregnated fabric formed from a monofilament polymer fiber in a mold, the monofilament fiber characterized by a softening point and a melting point; heating the mold and the unimpregnated fabric to a temperature greater than the softening point and less than the melting point; and cooling the mold.

Abstract: Materials and methods are provided for producing preform materials for impact-resistant composite materials suitable for liquid molding. Interlayers formed of nonwoven, continuous fibers, such as spunbonded, spunlaced, or mesh fabric, are introduced between non-crimped layers of unidirectional reinforcing fibers to produce a preform for use in liquid-molding processes to produce a composite member. Curing of the preform provides increased impact resistance by increasing the amount of energy required to propagate localized fractures due to impact.

Abstract: The present invention relates to a wood composite panel having a major planar portion, at least one panel portion, and an inwardly extending contoured portion surrounding the panel portion and interconnecting the major planar portion and the panel portion. The contoured portion defines an inter-relationship between a vector angle and a deep draw depth that achieve a satisfactory stretch factor. The present invention also relates to a door having the disclosed wood composite door facings, and methods of forming the facing and door.

Abstract: A device for making a seamless, anatomically contoured, prosthetic device for supporting or maintaining the position of mammalian tissue, organ or structure or a replacement thereof, such as a breast implant, includes a support plate, an ironing plate or a clamping plate and a core plate, each of which is made from a thermally conductive material. The support plate and the ironing or clamping plates have openings formed through the thickness thereof. The core plate has a core extending outwardly from a lower surface thereof which is received through the openings in the ironing or clamping plate and the support plate.

Abstract: A method for producing an article of composite material. A female molding tool is provided. A form bag is provided. At least one prepreg is placed in the molding tool. A heel shaped hard tool part. A hard tool part is placed at the female tool close to an edge of the laminate being placed in the mold. The form bag is placed in the female tool so that the bag seals towards the heel shaped tool part, in such a way that, at a later air evacuation of the bag, an increased pressure that the bag will apply towards the laminate reaches a radius before the pressure reaches an edge.

Abstract: Fabricating a test blade including defects for calibrating a tomography installation for verifying similar blades. A three-dimensional blank is made by weaving fibers of synthetic material and elements of resin in the solid state are inserted into predetermined locations in said blank prior to coating it in resin.

Abstract: A method for producing an aortic or mitral heart valve prosthesis and the resulting aortic or mitral heart valve. The method is characterized in that it essentially consists in producing the prosthesis by shaping a textile material. The invention is more particularly applicable in the field of medicine, in particular repair surgery, and especially in heart surgery, more particularly heart prostheses.

Abstract: A process of production of a monolithic article from a web of fibres of oriented polypropylene polymer, comprising the steps of subjecting the web to elevated temperature and pressure sufficient to melt a proportion of the polymer and compact it, and then cooling the compacted web, wherein an accelerated rate of cooling is employed down to 100° C. The process is of particular benefit when the weight average molecular weight (Mw) of the fibers is 250,000 or below. The resultant articles have good stiffness and strength, yet with reasonable ductility. Similar articles cooled slowly are brittle.

Abstract: The present invention relates to a method and a device for alleviating and/or preventing conditions relating to damaged joints. The device may be formed by moulding. Also the device may be formed with a hole or a slit to fit into the joint and lock the device around intra-articular components. A further aspect of invention relates to method for introducing the prosthetic device into a joint, such as a method comprising locking the device to an intro-articutar component. Also the invention relates to an instrument for inserting a prosthetic device according to the invention.

Abstract: A panel for use as quarter panel or quarter liner comprises a panel body formed of various layers of material pressed into a generally flat state. It also comprises a generally uniform outer surface for the panel body, the outer surface being flat in a malleolus region when the panel body is in the flat state. One or more concavities are defined in the inner surface of the panel body in the flat state and positioned in the malleolus region so as to received at least one malleolus of a wearer when the panel body is formed from the flat state into a boot shape. A method for forming a quarter panel or liner of a boot is also provided.

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

Abstract: There is disclosed a method for introducing a helical formation (11) into a flexible tubular material (12). The material (12) is supported together with a surrounding helical former (13) so as to deform the material (12) to have a helical indentation (11) corresponding to the shape of the former (13). The material (12) is then set in that configuration and the former (13) is removed.

Abstract: A thermal bonding pattern for nonwoven fabric possessing improved abrasion resistance while retaining softness, comprising a basket-weave pattern or other pattern having a transition area (2) equal to at least 10% of bonding spot area (1) in FIG. 3, more preferably a transition area (2) equal to at least 50% of bonding spot area (1), and most preferably a transition area (2) equal to at least 100% of bonding spot area.

Abstract: The present invention is a composite laminated sheet material suitable for structures such as containment sumps. The laminated material comprises a fabric-backed thermoplastic layer upon which thermoset plastic is applied to the fabric side. The thermoplastic layer is formed by contacting a layer of fabric onto a layer of molten thermoplastic such that the liquid thermoplastic permeates a portion of the fabric layer to form a mechanical bond with the fabric layer when the thermoplastic layer cools and hardens. Thermoset plastic, such as fibreglass resin, is sprayed onto the fabric side of the thermoplastic layer to allow the liquid resin to permeate the fabric layer. Once the resin cures and hardens, the fabric layer is mechanically bonded to the cured thermoset plastic layer to effectively bond the thermoplastic layer to the thermoset plastic layer.

Abstract: A robot hand member mounted on an arm unit of an industrial robot and a method of producing the same, wherein there are successively executed a step of laminating prepreg sheets each containing a reinforcing fiber on the outer peripheral surface of a core member having a predetermined shape in cross section, a step of heating the laminated prepreg sheets to a predetermined temperature to thermally set, to form a fiber reinforced plastic, and a step of removing the core member from the fiber reinforced plastic to obtain a hollow structure.

Abstract: The invention relates to a process for the production of a shaped article comprising the compression of one or more fibre layers containing polyolefin fibres. The invention also relates to shaped articles obtainable with the process according to the invention and their use in anti-ballistic applications. In the process according to the invention the fibre layers contain 0.02 to 25 wt. % of a solvent for the polyolefin. The shaped articles obtained have an improved anti-ballistic quality.

Abstract: A method of strengthening a boundary region between a first portion and a second portion of a fibrous body for absorbent articles. This boundary region is provided with a pattern of compressed spots, the amount of compression being gradually increasing in a direction leading away from an edge of the first portion of the fibrous body. Also, an apparatus for performing the method and an absorbent body having a strengthened boundary region.

Abstract: A filter pad comprises a pad (1) of non-woven fibrous material having a peripheral region in which opposing faces have been compressed together and fused so as to form an outwardly-extending peripheral lip (5). The filter pad is manufactured by providing a pad (1) of non-woven fibrous material, and compressing and heating a peripheral region of the pad so as to fuse the material of the pad and to form an outwardly extending peripheral lip (5).

Abstract: A method of producing a non-crimp fabric and a non-crimp fabric comprising a layup of fabric plies stitched together by a thread, at least part of which is fusible, is provided. The method can include heating the stitched plies to soften or melt the fusible thread. The use of fusible thread can act as an in situ binder within the non-crimp fabric and tension created by the unfused stitching may create channels for matrix resin infusion during manufacture.

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

Abstract: A process for producing a friction material based on a sheet-like carbon fiber woven fabric for wet-friction elements, such as clutch linings or synchronizing ring linings. The woven fabric of carbon fibers is impregnated with a binder, in particular with a resin, to form a binder-impregnated fiber material. The prepreg is cured for a curing period under a curing temperature which is elevated with respect to the ambient temperature and is pressed mechanically on its surfaces with a pressing mold before the start and/or at least during part of the curing period.

Abstract: There is provided a lightweight helmet shell including an inner shell formed from a porous expanded plastic layer, and an outer shell, in which the outer shell is formed from a compressed fiber sheet having an apparent density of 0.15 to 0.7 g/cc and an impact absorbability of less than 300 G. The lightweight helmet shell according to the invention has excellent breathability, is lightweight, and has improved impact absorbability.

Abstract: A production method for molding includes a. a first molding: depending on a shape to be molded, implementing a die feed-in on soft cloth, with the plastic that is injected in being fused and set with the cloth, for serving as a substrate layer; b. punching and trimming: punching and trimming the plastic that has been set to form a base; c. a second molding: implementing a second die feed-in on the base of a shaped product, with the injected-in plastic being fused and set with a surface of the base, to form the needed shape; d. tailoring and trimming: tailoring and trimming an edge interface between two layers of the assembled plastic to form a shaped product of a double-layer plastic on the soft cloth.

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: The present invention achieves differential transmit diversity and related diversity reception schemes transmit symbol constellations which are extended to multiple levels. Heretofore, a group of transmission bits is divided into a first sub-group of transmission bits and a second sub-group of transmission bits. Then, the first sub-group of transmission bits is mapped (14) onto constellation points of a differential transmit diversity coding scheme from an orthogonal design for coding of the first sub-group of transmission bits. Then, after differential encoding of the constellation points (32, 34, 36, 40) a length of the transmission symbol vector is scaled (38) for coding the second sub-group of transmission bits. Therefore, the present invention overcomes restrictions implied through unit length requirements for previously known differential transmit diversity schemes from orthogonal designs.

Abstract: The invention provides a method for simultaneously forming a surface texturing pattern (embossed pattern) on the surface of an FRP product when manufacturing the FRP product by hot-pressing a prepreg material. A prepreg material 2 is a woven sheet formed by weaving a weft 10 and a warp 20 which is impregnated with thermosetting resin 40. A release film laminate 100 formed by sandwiching an adhesive film 130 between release films 110 and 120 is placed on a surface to be provided with surface texturing, before subjecting the same to hot-pressing. The softening temperature of the adhesive film 130 is close to the curing temperature of the thermosetting resin 40, so as to allow the thermosetting resin 40 to be pushed into the space between hard FRP fibers during hot-pressing and to form the surface texturing pattern on the surface of the member.

Abstract: To provide a reinforcing woven fabric, which is excellent in deformability, capable of following a complicated shape and excellent in retention of the shape, and a preform using it, a fiber reinforced plastic molded component and a process for producing them. Provided is a reinforcing woven fabric where a resin material is stuck on at least one surface of a fabric substrate containing a plurality of reinforcing fiber bundles, then the resin material stuck over two or more reinforcing fiber bundles is peeled from a part of the two or more reinforcing fiber bundles by varying the relative position of a plurality of reinforcing fiber bundles constituting the fabric substrate, wherein the maximum value of load till a tensile strain in a non fiber axial tensile test reaches 1% is in a range of 0.01 to 0.75 N.

Abstract: An apparatus for applying to the cups of a bra, or to the overall bra, a casing for housing therein a cup supporting element, comprises at least two bobbins, one supporting a resilient element or casing, and the other supporting an adhesive having a protective silicone processed paper, a first hot-applying device for binding the casing to the adhesive material, and a programmable tensioning device, applying to the adhesive processed casing an adjustable pulling force.