Abstract: A method to produce a fabric reinforced hose product in which the reinforcing fabric therein has a stabilizing yarn therein extending in the longitudinal direction of the hose which is broken when the produced hose member has been flexed in the longitudinal direction.

Abstract: Glass fiber mats are made for subsequent use in preforming for an RTM or SRIM molding process, for example, such that the binder applied to the mat has two distinct curing stages. In the first stage, a partial cure is provided by visible light upon a free radical generation in response to a photoinitiator mixed in the binder in an exact ratio to give a predictable increase in viscosity to that of a semi-solid so that the fibers are sufficiently bound for subsequent handling, but not sufficient to complete a cure, while leaving a second stage ready for a final cure which is achieved by the use of a cationic-type second photoinitiator which is sensitive to ultraviolet light. During the second curing stage, the mat is formed into a three-dimensional shape of a desired end product and cured with ultraviolet radiation while still in the mold, to obtain a rigid three-dimensional preform structure.

Abstract: A rigid three-dimensional preform is made by moving a plurality of webs of fibrous reinforcement material superposed and coplanar to a cutter, the webs being coated with an electromagnetic energy-curable binder and pressed together. Prior to cutting a blank in a two-dimensional development of the three-dimensional preform from the webs, the webs are tacked together at spaced local zones by locally curing the binder at those zones by locally applying the appropriate electromagnetic radiation (microwave, ultraviolet, electron) so that the webs travel as one to the cutter. After cutting of the blank, the blank is loaded into a mold to replicate the three-dimensional shape of the preform and the remainder of the binder is cured in the mold by the application of the appropriate electromagnetic radiation.

Abstract: A method of progressively molding and curing/homogenising a composite material component assembly including a skin panel and a series of spaced structurally reinforcing members therefor. The method includes the steps of placing a composite material layer (18) on support (13), clamping same to the support by a mold including first and second tools (14/16), the second tool being separated from the first tool by a pre-determined amount, slidably moving the second tool (16) towards the first tool (14) to cause the material to fold in an upwards direction until clamped between datum faces (15, 17) of the tools to define the structural member, heating the support (13) and tools (14, 16) to cure/homogenise the skin panel and structural members, then slidably moving the component along the support (13) a pre-determined amount to draw a further quantity of composite material layer (18) from a source and repositioning the tools (14, 16) for further processing of the material.

Abstract: The invention provides a control system and method for curing composite articles such as corrugated fiberglass resin plastic (FRP) panels. An exemplary system of the invention includes a curing oven, at least one infrared pyrometer sensor which is located within the oven curing zone and which provides an output indicating the temperature of the resin being cured, a tractor unit for moving the panel through the oven, and a comparator circuit which adjusts the speed of the tractor unit in predetermined response to sensor output. The invention thereby provides for the detection of the peak temperature or gelation point of resin in the panel, and allows its specific location in the oven to be controlled to optimize the performance and efficiency of the panel production line.

Abstract: This invention relates to liners containing contaminants, such as styrene, and to methods for lining pipes, such as sewer pipes with liners containing contaminants, such as styrene. In one embodiment, this invention provides a liner and lining method that reduces contamination of the ambient with contaminants from the liner and/or the lining process, such as styrene. In the case of sewers, the carrier pipes lined may be, for example, PVC, clay or concrete, but pipes of metal or other materials, such as asbestos, may also be lined with the liner and lining method of this invention.

Abstract: A method of molding a plastic-backed carpet blank to a desired shape uses a minimum of work force and carpet material. The method utilizes a portable frame assembly having an open rack with yieldable holding clamps. The holding clamps are used to suspend a plastic-backed carpet blank in the rack. The frame assembly has a set of wheeled legs which allows it to be readily transported between work stations such as a heating zone and a molding zone. The yieldable holding clamps maintain the carpet under constant tension during the molding zone to result in a high quality molded carpet.

Abstract: A method of producing fiber reinforced plastic moldings.

Abstract: Shaped products are prepared by molding composite materials based on a fabric consisting of at least two superimposed single-directional layers of continuous fibers stitched together with thread, with the continuous fibers being oriented in different directions from each other. The composite fabric is stamped in a die by means of a stamp while applying at the same time a monitored tension to the fabric as the fabric is forced into the hollow of the die by a stamp. The monitored tension is modulated by interposing relaxation stages having a value slightly greater than zero. The fabric, while maintained under monitored tension, is impregnated with a quantity of resin or binder needed for the formation of the finished part.

Abstract: A process for the production of shaped lined panels, of the type wherein the lining is positioned on a frame including a series of reference and adjusting pivots capable of being reversibly engaged by a pluality of corresponding reference holes provided on the lining. The process positions the pivots on the frame according to an arrangement which is a function of the arrangement of said plurality of holes in the covering and the shaped and correctly lined panel.

Abstract: A method for forming structural injection molded parts includes the steps of positioning a closed-loop cutting blade in surrounding relation to one of a male and female mold which together define a mold cavity corresponding to the shape of a part to be molded, positioning reinforcing material over the female mold, moving the male mold into the female mold to position the reinforcing material in the mold cavity, thereafter moving the cutting blade independently of the mold which it surrounds to trim the reinforcing material, and injecting resin into the mold cavity to produce a structural injection molded part. The cutting blade and the mold which it surrounds are part of and movable with a common die set assembly having a lost motion drive connection between the mold and the cutting blade, such that the trimming step is accomplished by lost motion movement between the mold and the cutting blade after the male and female molds have been mated.

Abstract: A process for producing high-temperature resistant and flame-retardant shaped articles of polyimide polymers of the general formula ##STR1## wherein A represents a four-valent group and R represents a divalent aromatic group, by heating a manipulatable sheet-like structure to a temperature in the glass transition range of between 280.degree. C. and 360.degree. and pressing it at pressures ranging between 10 bar and 500 bar. The polyimide shaped bodies obtained have densities of at least 1.30 g/cm.sup.3. Preferably, they may be completed as sheets having uniform thicknesses of between 0.1 and 6 mm.

Abstract: An end cell for a chromatography column has a moulded plastics structure and an integral screen formed of a woven mesh of fibres of the same plastic material as used for the end cell. A peripheral ring of the same plastics material is injection moulded to the perimeter of the mesh, said ring being secured to the end cell in a leak-proof manner, preferably by ultrasonic welding.

Abstract: A process for injection molding a thermoplastic backing (12) or other synthetic resin to a carpet layer (14) by suspending the carpet layer (14) between two mold halves (46,48), injecting a thermoplastic resin into the mold, and injecting an inert fluid such as nitrogen into the mold at a relatively low pressure to assist in distribution of the thermoplastic resin throughout all points of the mold. The invention also relates to a synthetic resin backed carpet, which resin backed carpet may constitute a vehicle dashboard (10). The vehicle dashboard (10) can include an internal runner or rib (16) which has a hollow portion (52) formed substantially along its length, the hollow portion (52) being formed by injection of the inert fluid during the injection molding process.

Abstract: A method for the injection molding of a laminate article having a deformable material sandwiched between a textile layer and a thermoplastic substrate and bonded into a unitary assembly by the thermoplastic. The laminate is molded into a sheet form for deformation to a preselected shape in a die-forming operation.

Abstract: A method and apparatus for manufacturing perforate, fiber reinforced composite material wherein the fiber reinforcing material is impregnated with the resin which is cured to give a strong light material.

Abstract: A network of non-porous polyethylene fibers substantially free of voids formed by preparing a network of gel spun fibers, applying pressure to the network at a temperature and pressure and for a time adequate to form a translucent film substantially free of voids.

Abstract: The invention is a method of consolidating and forming a composite part having a plurality of principle surfaces, the part made from a preform having a filamentary material in a resin matrix. The method comprising the steps of placing sheets of material on each of the principle surfaces of the preform; clamping a portion of the preform and the sheets of material together in a moveable clamp; and pultruding the preform with the sheets of material on the principle surfaces through a consolidation and forming zone of a die by moving the clamp.

Abstract: A new process for producing a reproduction of a painting or the like wherein the reproduction has a relief surface which imitates the relief surface of the painting or the like. Heat and pressure are applied simultaneously to an assembly consisting of a mold of the painting, a colored sheet for coloring the reproduction and a substrate to retain the reproduction. Subsequent to this step, shock cooling is applied. The reproduction thus produced does not suffer from the rebound effect of the prior art and good color integrity is maintained.

Abstract: For forming a resin-impregnated, fiber reinforced composite material sheet having laminated meshes of fibers into a U-shaped cross section, the sheet is placed onto a stationary forming die and an auxiliary forming die with the fibers of the sheet forming angles of approximately 45.degree. relative to opposite edges of an upper reference forming surface of the stationary die. Then, the sheet is pressed from above by a pneumatically expandable, elastic depressing die, whereby the auxiliary forming die is lowered against a resilient force relative to the stationary forming die. As the sheet is pressed further downwardly by the depressing die, the parts of the sheet which are to form flanges of the product are firmly held between the depressing die and the auxiliary forming die and bent downwards while the parts are subjected to extending forces in directions to prevent creases and lines from being formed by means of auxiliary forming ridges on the auxiliary forming die.

Abstract: A process for curing a polymeric article formed from a fiber material inpregnated with uncured phenolics, unsaturated polyesters, epoxides, or silicones. The process involves placing the uncured article into a non-gas tight pressure chamber, packing the chamber with lubricated beads, and heating the article under pressure. Additionally, fiber-reinforced thermoplastics may be heat shaped in the presence or absence of a mold.

Abstract: A paperboard, containing a major portion of cellulose and a minor portion of an uncured biodegradable latex polymer, is molded into a shaped packaging form.

Abstract: A fusion bonded fiber product is made by compressing between heated dies a mat of moisture-containing fibers of the type that change irreversibly to an amorphous nonglassy state that permits fiber-to-fiber bonding at a characteristic critical temperature. The further compression of the partially compacted mat is stopped or slowed when the mat is a small multiple of the desired caliper for the bonded product for a period of time sufficient to vaporize the moisture content of the mat. During this time period, most of the vaporized moisture content of the mat is expelled as saturated steam through the mat surfaces while the temperature of the mat is still well below the critical temperature. Then, the compression of the mat is continued under continuous consolidation to the final density and caliper of the fusion bonded product while the mat is heated to a temperature above the critical temperature.

Abstract: A method for continuously vulcanizing a self-molding hose by external heating including the steps of first forming continuous strip of self-molding material which includes a heat-shrinkable woven fabric, a first vulcanized elastomer topping layer provided on a top surface of the heat-shrinkable woven fabric, a second vulcanized elastomer topping layer provided on an undersurface of the fabric with the second vulcanized elastomer topping layer being thinner than the first vulcanized elastomer topping layer and an unvulcanized elastomer topping layer provided on the undersurface of the second vulcanized elastomer topping layer. Then the continuous strip is overlappingly wound on a former to create a circular hose and the circular hose is continuously introduced into a gap between rotary drums of vulcanization apparatus at the same rate as the rate of the circular hose formation so that the circular hose is pressed flat, heated and vulcanized and converted into a flat hose.

Abstract: A method of fabricating structures formed from composite materials by positioning the structure about a high coefficient of thermal expansion material, wrapping a graphite fiber overwrap about the structure, and thereafter heating the assembly to expand the high coefficient of thermal expansion material to forcibly compress the composite structure against the restraint provided by the graphite overwrap. The high coefficient of thermal expansion material is disposed about a mandrel with a release system therebetween, and with a release system between the material having the high coefficient of thermal expansion and the composite material, and between the graphite fibers and the composite structure. The heating may occur by inducing heat into the assembly by a magnetic field created by coils disposed about the assembly through which alternating current flows. The method permits structures to be formed without the use of an autoclave.

Abstract: A method for forming stabilized preforms for complex composite articles is disclosed using a solid meltable uncatalyzed thermosetting resin as the stabilizing agent. The resin is applied to each layer of the preform and heated to melt the resin and bond the layers together. After cooling, the resin resolidifies but does not set and thereby holds the layers in the desired preform shape. The layers can be first formed into a flat sheet as a raw material from which shaped preforms can be made by cutting the sheet into sections which are placed over a mandrel and reheating to thereby remelt the solid resin to allow the preform to conform to the shape of the mandrel. Utilizing this process allows complex composite parts to be easily preformed and assembled prior to placement in a mold for resin injection molding, without inhibiting part strength as the resin is compatible with the injection resin and is cocatalyzed by the catalyst contained in the injection resin.

Abstract: A method of making a heat-resistant paper container which comprises a bottomed seamless press-molded body comprising a laminate of a paper substrate having an elongation of at least 1.5% in the longitudinal direction and an elongation of at least 4.5% in the lateral direction and a coating layer of a hiding pigment formed on both the surfaces of the paper substrate, wherein the amount coated of the hiding pigment is 1 to 50 g/m.sup.2, the binder in the coating layer is a thermosetting resin binder and the binder is present in the coating layer at a weight ratio R.sub.P satisfying the following condition:R.sub.P =k.multidot.O.sub.A .multidot.d.sub.Rwherein O.sub.A stands for the oil absorption (ml/100 g) of the hiding pigment, d.sub.A stands for the density (g/ml) of the binder, and k is a number of from 0.005 to 0.2.

Abstract: An elastomer-coated fabric for use as a confinement. The confinement is formed by conforming a fabric to a mold having the shape of the desired confinement, and subsequently applying a layer of elastomer to the fabric. A curing operation then cures the elastomer such that the elastomer-coated fabric retains the shape of the mold. Advantageously, the curing operation also relaxes and heat sets the fabric in order to permit a controlled amount of further stretch, even if the fabric was stretched a maximum amount when it was conformed to the mold.

Abstract: Preforms for molding processes such as resin transfer molding processes are prepared by melting a solid, non-sintering, thermoplastic-like resinous compound on the surface of a substrate material. After cooling, assembling one or more plies of the coated substrate material into the desired shape; heating the shaped substrate material to a temperature above the melting temperature of the resinous compound and subsequently cooling to a temperature below the melting point of the resinous compound.

Abstract: Molded carpet for use in motor vehicles is made by a method which allows the molding of carpet having deep well areas. The method comprises the steps of heating a plastic backed carpet blank to a degree to make its backing pliable and thereafter molding the heated carpet in a set of specially constructed molds. The molds generally have the shape of the floor area to be covered. However, they are arch-shaped from edge to edge at those portions of the mold where draws are needed to accommodate specially contoured well areas of the motor vehicle's floor area.

Abstract: In order to make a synthetic membrane for a gas meter of the measuring chamber type, an initial structure (10) of polyester fibers (11), which are preferably woven, is placed between two films (26, 28) of hot meltable elastomer (polyurethane). The hot meltable material is raised to its softening temperature and pressure is applied to cause the films (26, 28) to adhere to the woven structure (10).

Abstract: A spherical sealing body is to be inserted in a space defined by three of an end edge of an exhaust pipe on upstream side, a flange fixed on an outer periphery of the exhaust pipe on upstream side, and a concave spherical portion disposed on an end edge of an exhaust pipe on downstream side. The spherical sealing body includes a wire mesh body obtained through weaving or knitting a fine metal wire, the metal mesh body has a cylindrical inner circumferential surface to be fitted in an outer circumferential surface of the exhaust pipe on upstream side, a convex outer circumferential surface to be fitted in the concave spherical portion, and a bottom surface on large diameter side to be abutted against the flange. A refractory material is filled in meshes and clearances of a part of the wire mesh body corresponding to the convex outer circumferential face and the bottom face.

Abstract: A mold structure including layers with different physical properties is used to provide hot surface during molding. The use of a thin layer of low thermal conductivity covered by a smooth skin layer prevents quick cooling of the surface of the pre-heated plastic to be molded. The plastic surface remains molten and flows to fill the mold during press closing, resulting in smooth surfaces even when fiber reinforced plastics are used.

Abstract: A process for continuously forming reinforced articles (24) which includes producing a reinforcing material (13) having a plurality of superimposed layers (1-6), stitching together said layers (1-6), wetting said reinforcing material (13) with a matrix material (7, 8 or 19), forming the wetted reinforcing material and curing or consolidating the matrix material. Each layer (1-6) of the reinforcing material (13) includes a plurality of unidirectional non-woven yarns or threads (10) laid side-by-side, the yarns or threads (10) in at least some of the different layers (1-6) extending in different directions. Forming of the wetted reinforcing material may be effected by moulding, pultrusion or by wrapping wetted reinforcing material around a mandrel or former (25).

Abstract: A method for curing fiber-reinforced resin matrix composite materials (22) includes the steps of providing a form (14) and positioning uncured composite material (22) on the form (14) substantially into a desired shape. The composite material (22) is then cured by providing a fluid bath (10) heated to a predetermined temperature, and heating the composite material (22) by immersing the positioned composite material (22) on the form (14) into the fluid bath (10) for a predetermined time. The predetermined time is sufficient to allow the composite material (22) to become cured and to heat the composite material (22) at a rate sufficient to provide resin flow prior to hardening. Compressive pressure is provided on the composite material (22) while it is immersed in the fluid bath (10).

Abstract: A method of making a fire hose including the steps of extruding a tube having inner 12 and outer coverings of elastomeric material on a woven jacket made from woven synthetic textile yarns and having a weft which is unusually highly crimped. The extruded tube is placed in a confining mould or sheath having an internal diameter substantially the same as the external diameter of the hose, curing the material of the tube by internal application of heat and pressure, pressing the outer covering into tight engagement with the sheath. The sheath effectively prevents radial expansion of the hose during the curing and the outer covering is thus embossed with the surface topography of the inner surface of the sheath upon removal of the sheath. The hose thus formed has good diametral swell properties and consequently reduces the frictional forces in relation to the amount of water flowing through the hose.

Abstract: A method of making a shaped article from at least one integrated multi-layered sheet having excellent mechanical properties and being light in weight, which includes the steps of providing a thermoplastic synthetic material reinforced by a fiber mat on at least one side of a substantially flat sheet of thermoplastic synthetic foam having a homogeneous structure, the fiber mat, thermoplastic synthetic material and sheet of synthetic foam being integrated under the influence of elevated temperature and increased pressure, providing deformability by entirely or locally heating the resulting integrated fiber reinforced sheet, giving the heated sheet the desired structure and shape, and fixing the article by cooling.

Abstract: A method for heating and press-forming a plied material sheet prepared by impregnating a thermosetting resin into sheets of parallely disposed plastic fiber or into sheets of woven fabric of plastic fiber. The material sheet is formed into an operation which repeats the steps of heating and press-forming such material sheet within a shaping mold on a heating and press-forming apparatus for a predetermined time period and then releasing the pressure for a predetermined time period while step-feeding the material sheet over a predetermined distance for a time period less than the time period of such released pressure.

Abstract: A method for incrementally mold-forming sections of a fiber reinforced, thermoplastic material into a composite product which has a mold product configuration of non-uniform cross section and/or non-linear configuration. Large laminates are formed by utilizing small to medium sized molds to successively mold incremental sections of the total product. Each section of the laminate is first heated to a flowable condition and is then compressed within the mold cavity to form the desired incremental shape. This process is completed until all parts of the product have been formed utilizing variations in mold components to change geometries within the total part.

Abstract: Disclosed is glass fiber reinforced thermoplastic sheet material suitable for various compression molding applications. The glass fibers useful in this invention are described in detail, and the thermoplastic composition is poly(ethylene terephthalate), poly(cyclohexylene dimethylene terephthalate) or a blend of either of these polyesters with each other and/or polycarbonate.

Abstract: A method for molding high temperature composites that transmits more uniform pressures to the surface of the composites. A compliant glass, glass-ceramic, or ceramic layer is caused to apply pressure to a composite precursor and heat is applied to the composite precursor to form a composite.

Abstract: A method of molding thermoplastic material into a collar for use on a drill string is disclosed. Initially a precursor is constructed by rolling a sheet of thermoplastic material, containing long reinforcement fibers, into a tubular "roll" and placing the roll in a generally cylindrical open mold so as to align longitudinal axes of the roll and the open mold. A cylindrical mold core, which mates with the open mold to form a mold cavity, has an end piece perpendicular to the cylindrical portion for closing the mold. The mold core is forced, with correct alignment, into the open mold using high pressure which closes the mold and causes the thermoplastic material, containing long reinforcement fibers, to take the required shape. The thus formed part is cooled and ejected from the mold for use as the precursor. Final steps include machining the ends of the precursor to produce the desired collar.

Abstract: An elastomer-coated fabric for use as a confinement. The confinement is formed by conforming a fabric to a mold having the shape of the desired confinement, and subsequently applying a layer of elastomer to the fabric. A curing operation then cures the elastomer such that the elastomer-coated fabric retains the shape of the mold. Advantageously, the curing operation also relaxes and heat sets the fabric in order to permit a controlled amount of further stretch, even if the fabric was stretched a maximum amount when it was conformed to the mold.

Abstract: Preforms for molding processes such as resin transfer molding processes are prepared by melting a solid, non-sintering, thermoplastic-like resinous compound on the surface of a substrate material; after cooling, assembling one or more plies of the coated substrate material into the desired shape; heating the thus shaped substrate material to a temperature above the melting temperature of resinous compound and subsequently cooling to a temperature below the melting point of the resinous compound.

Abstract: A method of making fiber reinforced composite articles from stabilized dry fiber preforms which are impregnated with a thermosetting resin by the resin transfer molding method. The dry fiber preforms may be stabilized prior to molding by dispersing a polymeric binder between adjacent dry fabric plies of the preform. Hot air is passed through the preform after it has been compressed to fuse the binder and bind the dry fabric plies together, forming a stabilized high density fiber preform. Forming a preform by this method is significantly less labor and time intensive than methods currently in use.

Abstract: A layer of a neat resin in powder form is deposited either on a mold surface or on a bulk thermoplastic composite fiber reinforced sheet. The resin layer is adjacent to an insulated wall of a compression mold. The bulk sheet is preheated and compression deformed with the powdered resin. The heat from the sheet flows to and melts the powder layer producing a resin rich layer. The insulated wall permits the heat of the sheet to be retained sufficiently to melt the powdered resin. In the alternative, the neat resin powder may be replaced with a preformed film of thermoplastic resin compatible with the sheet resin. A structural homogeneous integral molecular bond is formed between the neat resin layer and the sheet.

Abstract: Process for producing a light steering wheel having a central hub, a peripheral rim and radial arms interconnecting the hub and the rim. The process is carried out by using a mould including a punch and a matrix having an impression in the shape of the steering wheel to be produced. The impression is at least partially filled with blanks of synthetic material charged with long fibers which are uninterrupted in each blank. The steering wheel, in the shape of the impression, is directly produced in one operation by stamping the blanks in the mould with the punch to shape the blanks into the steering wheel. The blanks are placed edgewise in the mould and are unshaped relative to the shape of the produced steering wheel.

Abstract: The method includes the steps of coating the peripheral surface of a roll with a film of plasticizer. An offset roll disposed adjacent to the roll is rotated such that the roll and the offset roll define therebetween a transfer nip so that a film of the plasticizer is transferred to the offset roll. The web is moved past the offset roll such that the web contacts the offset roll downstream relative to the transfer nip so that the film of the plasticizer is offset onto the web. The web is then passed with the offset coating of plasticizer through a calendering nip such that between the offset coating of the web and the subsequent calendering of the web with the offset coating, the plasticizer is permitted to uniformly and controllably penetrate into the web such that the Z-directional compressibility of the web is controlled prior to the web extending through the calendering nip.

Abstract: A new process for producing a reproduction of a painting or the like wherein the reproduction has a relief surface which imitates the relief surface of the painting or the like. Heat and pressure are applied simultaneously to an assembly consisting of a mold of the painting, a colored sheet for coloring the reproduction and a substrate to retain the reproduction. Subsequent to this step, shock cooling is applied. The reproduction thus produced does not suffer from the rebound effect of the prior art and good color integrity is maintained.

Abstract: A method of producing a resin molded article composed of a base material of a synthetic resin and a surface layer provided on the surface of the base material as one body, which includes preparing a mold having a cavity with an end molding portion for molding the end portion of the resin molded article and a body molded portion for molding the body of the resin molded article, the width of the end molding portion being larger than that of the body molding portion. The surface layer is disposed within the cavity of the mold, while disposing molten synthetic resin for the base material on one side of the surface layer so as to be held in the cavity of the mold. The mold is then closed and compressed gas is injected into the molten synthetic resin within the end molding portion so as to expand the molten synthetic resin. Finally, the molten synthetic resin is cured in the cavity.