Patents Assigned to Composite Products, Inc.
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Publication number: 20070114698Abstract: A molding apparatus is configured with a distribution channel configured to deliver a blended feed composition directly into an article molding region such that a molded article is formed with gating on the bottom surface of the article. The article molding regions are formed into front sides of opposed “A” and “B” surface mold tools that, when moved into a mating relationship with one another, form closed molding cavities within which molded articles are generated from molding material feed. The article molding regions each generally have a body bounded by a perimeter that establishes an outer edge for an article molded in the one of the closed molding cavities. Additionally, the body of each article molding region of the “A” surface mold tool is adapted for molding a bottom surface for the composite article, and the body of the article molding region of the “B” surface mold tool is adapted for molding a top surface for the composite article.Type: ApplicationFiled: November 21, 2005Publication date: May 24, 2007Applicant: Epoch Composite Products, Inc.Inventors: Dennis Carlson, Dan Robinson
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Publication number: 20070114697Abstract: A molding apparatus is configured with article molding regions that receive a direct flow of a molding material feed such that external flow channels are not needed. The article molding regions are formed into front sides of opposed “A” and “B” surface mold tools that, when moved into a mating relationship with one another, form closed molding cavities within which molded articles are generated from molding material feed. The article molding regions each generally have a body bounded by a perimeter that establishes an outer edge for an article molded in the one of the closed molding cavities. With at least the “A” surface mold tool, a port is coupled with the body of each article molding region to establish a direct pathway is through which the molding material feed flows to enter the article molding regions, and thus the closed molding cavity, without having to flow along the tool front sides outside of the article molding regions.Type: ApplicationFiled: November 21, 2005Publication date: May 24, 2007Applicant: Epoch Composite Products, Inc.Inventor: Dan Robinson
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Patent number: 7178294Abstract: The present invention generally encompasses a ridge cap roofing product that is formed from a composite material. The ridge cap has a cross section that is generally in the shape of an inverted V with a rounded apex and includes a front section and a back section. The front section has a straight lower edge. The back section has a lowered edge that tapers both upward and inward. The tapered shape of the ridge cap's back section insures that installed ridge caps lie flat and that a covered ridge or hip does not have a saw tooth appearance. The ridge cap of the present invention is somewhat flexible so that it can be used with roofs that have a range of pitches. In one embodiment, the top surface of the ridge cap's front section is textured or contoured so that it simulates certain conventional shingles.Type: GrantFiled: January 14, 2004Date of Patent: February 20, 2007Assignee: Epoch Composite Products, Inc.Inventor: Randal J. Jolitz
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Patent number: 6935089Abstract: Methods of making roofing products. One such method includes (a) creating a mixture having a filler and a polymer; (b) forming a sheet from the mixture; (c) cooling the sheet; (d) embossing the sheet; (e) forming multiple roofing products from the sheet; and (f) bundling at least some of the roofing products. Steps (a)-(f) are performed using an automated procedure. Another of the methods involves (a) creating composite roofing products using mold cavities; (b) using a robot to transfer some of the roofing products from some of the mold cavities to a conveying system; and (c) stacking together at least two of the roofing products that have different colors or different surface configurations.Type: GrantFiled: March 12, 2003Date of Patent: August 30, 2005Assignee: EPOCH Composite Products, Inc.Inventors: Randal J. Jolitz, Dennis Dean Carlson, Charles Doyle Ziulkowski
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Patent number: 6925857Abstract: A method of determining an average length of reinforcing fiber in a sample of reinforcing fibers is disclosed. A sample of reinforcing fibers is weighed to obtain a total sample weight. The sample of reinforcing fibers is placed in a fiber separating mechanism and suspended in water. The water is stirred after which the water is allowed to settle such that the sample of reinforcing fiber divides into a plurality of fractions in separate sections of the fiber separating mechanism. Each fraction has reinforcing fibers of substantially similar lengths and is separately weighed. An average fiber length is calculated from the relative weights of each of the plurality of fractions and the total sample weight. In addition, a method of determining an average length of a reinforcing fiber in a composite material having a resin and a plurality of reinforcing fibers is disclosed.Type: GrantFiled: August 5, 2004Date of Patent: August 9, 2005Assignee: Composite Products, Inc.Inventors: Charles Weber, Chris Rannenberg
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Publication number: 20050005685Abstract: A method of determining an average length of reinforcing fiber in a sample of reinforcing fibers is disclosed. A sample of reinforcing fibers is weighed to obtain a total sample weight. The sample of reinforcing fibers is placed in a fiber separating mechanism and suspended in water. The water is stirred after which the water is allowed to settle such that the sample of reinforcing fiber divides into a plurality of fractions in separate sections of the fiber separating mechanism. Each fraction has reinforcing fibers of substantially similar lengths and is separately weighed. An average fiber length is calculated from the relative weights of each of the plurality of fractions and the total sample weight. In addition, a method of determining an average length of a reinforcing fiber in a composite material having a resin and a plurality of reinforcing fibers is disclosed.Type: ApplicationFiled: August 5, 2004Publication date: January 13, 2005Applicant: Composite Products, Inc.Inventors: Charles Weber, Chris Rannenberg
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Publication number: 20040178532Abstract: A method of making a roofing product such as a shingle is provided. One such method includes creating a mixture having at least a polymer and a filler, forming a sheet from the mixture, cooling the sheet, embossing the sheet, forming multiple roofing products from the sheet and bundling at least some of the roofing products together. This method is performed using an automated procedure. Another method of the present invention involves creating a composite roofing product using mold cavities, using a robot to transfer some of the roofing products from some of the mold cavities to a conveying system, and stacking together at least two of the roofing products that have different colors of different surface configurations.Type: ApplicationFiled: June 9, 2003Publication date: September 16, 2004Applicant: EPOCH Composite Products, Inc.Inventors: Randal J. Jolitz, Dennis Dean Carlson, Charles Doyle Ziulkowski
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Patent number: 5824249Abstract: A method for fabricating molded parts utilizing a plurality of mold details having respective molding surfaces defining respective contours. The method selecting a first group of the mold details and disposing the selected mold details adjacent to one another in a first predetermined spatial relationship so that the molding surfaces of the selected mold details are contiguous, to define a first molding cavity for producing a first desired molded part. A hardenable polymeric material is injected into the molding cavity and hardened to form the desired molded part. Various combinations of mold details can be assembled to produce multiple parts in a common mold frame.Type: GrantFiled: February 28, 1996Date of Patent: October 20, 1998Assignee: Dow-UT Composite Products, Inc.Inventors: James Leitch, Richard Olds
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Patent number: 5817265Abstract: An apparatus and method provide for the assembly of a multiply shaped fiber preform, the apparatus using a shaping tool having the shape of the desired part, and one or more secondary location tools, can be positioned on the shaping tool, so as to simulate a flat shape. The location tools include a number of upwardly extending location pins, such that a number of plies can be assembled in a vertical stack using the pins to assure ply to ply accuracy and orientation. After assembly, the plies are engaged in a localized portion of the assembly so as to hold the plies in register, with the secondary tools then removed and the plies then formed to shape over the tool surfaces. Utilizing the apparatus and method of the invention maintains multiple plies in register during the assembly and forming process to assure part reproducibility, in an automated process.Type: GrantFiled: October 3, 1995Date of Patent: October 6, 1998Assignee: Dow-United Technologies Composite Products, Inc.Inventor: Johnny Paul Gendreau
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Patent number: 5784926Abstract: A fiber reinforced composite hub has a plurality of fiber reinforced spokes having first portions which define a drive shaft bore and second portions which mate to an innermost layer of a fiber reinforced flywheel rim. Both the rim and hub are preferably produced as stabilized preforms which are integrally or separately formed, then assembled and placed into a mold for molding into a unitary structure.Type: GrantFiled: August 27, 1996Date of Patent: July 28, 1998Assignee: Dow-United Technologies Composite Products, Inc.Inventor: David Maass
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Patent number: 5778736Abstract: A fiber reinforced composite flywheel for energy storage has a plurality of disks in the form of a coil produced of continuous hoop and radial fibers, each disk having a mix of fiber types in the hoop direction, relatively strong fibers disposed about an inner section of the disk, an intermediate section of the disk comprised of relatively strong and relatively lower strength fibers, and an outer portion having a mix of fibers fewer relatively strong fibers. A fiber reinforced composite flywheel, alternatively or in addition, has a higher volume of radial fibers disposed about the intermediate section of the disk, to increase radial strength in a banded area of the disk subject to increased radial stress. Preferably, the disk is composed with a 3-dimensional orthogonal weave architecture which allows the fibers to shear during weaving to provide minimum distortion of the spiral woven disk.Type: GrantFiled: June 12, 1996Date of Patent: July 14, 1998Assignee: DOW-United Technologies Composite Products, Inc.Inventors: David Maass, Douglas M. Hoon
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Patent number: 5650229Abstract: A fiber filler for filling voids between mated fiber plies, for example, as occurs in the preparation of a preform assembly for forming a T-shaped structural member, is disclosed. The fiber filler comprises a plurality of unidirectional fibers, shaped to conform to the shape of the void and a stabilizer intermingled with the unidirectional fibers. The stabilizer is present in an amount sufficient to hold the fibers together in the shape of the void, but below an amount which would inhibit resin flow during subsequent injection, so that the fiber filler is fully integrated into the final part.Type: GrantFiled: August 15, 1996Date of Patent: July 22, 1997Assignee: Dow-United Technologies Composite Products Inc.Inventors: Ronald David Gross, Brett David Kushner
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Patent number: 5624618Abstract: A multi-vane structure for incorporation in an aircraft gas turbine engine has vanes of complex geometry made of braided fibers which are continuous about the cavities defined by the vanes. These complex geometry parts are prepared by providing a plurality of removable mandrels, stacking the mandrels along a horizontal axis in a cavity end to cavity end configuration, braiding about the mandrels, cutting the mandrels adjacent the cavity end faces, side stacking the mandrels so the faces are placed in a parallel orientation and molding. Utilizing braided fibers instead of hand lay-up woven fibers eliminates seams and produces cavities having continuous fibers about the periphery thereof which substantially increases the strength and dimensional reproducibly of the part.Type: GrantFiled: June 7, 1995Date of Patent: April 29, 1997Assignee: Dow-United Technologies Composite Products, Inc.Inventors: Thomas P. Forman, Rance B. Fox, George E. Sabak, Timothy A. Sands, Paul A. Vallier
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Patent number: 5581968Abstract: A connector assembly for siding panels to form a self-flashing, leakproof seam between the ends of the siding panels. The connector assembly includes first and second connectors each attachable to an end of a siding panel. Upon securement of the connectors to the siding panel, the siding may be applied to the building with the connectors overlapping preventing longitudinal separation. The vertical channels of the connectors allows sliding engagement of the siding.Type: GrantFiled: June 28, 1995Date of Patent: December 10, 1996Assignee: Composite Products, Inc.Inventors: Gregg A. Laurie, Larry A. Demaree
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Patent number: 5576079Abstract: A multi-vane structure for incorporation in an aircraft gas turbine engine has vanes of complex geometry made of braided fibers which are continuous about the cavities defined by the vanes. These complex geometry parts are prepared by providing a plurality of removable mandrels, stacking the mandrels along a horizontal axis in a cavity end to cavity end configuration, braiding about the mandrels, cutting the mandrels adjacent the cavity end faces, side stacking the mandrels so the faces are placed in a parallel orientation and molding. Utilizing braided fibers instead of hand lay-up woven fibers eliminates seams and produces cavities having continuous fibers about the periphery thereof which substantially increases the strength and dimensional reproducibly of the part.Type: GrantFiled: August 16, 1994Date of Patent: November 19, 1996Assignee: Dow-United Technologies Composite Products, Inc.Inventors: Thomas P. Forman, Rance B. Fox, George E. Sabak, Timothy A. Sands, Paul A. Vallier
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Patent number: 5496602Abstract: A low resin content unidirectional fiber tape is disclosed for use in incorporating unidirectional fibers in dry fiber preform for use in a resin transfer molding process. A plurality of unidirectional fibers are located between a pair of thin flexible resin films which hold the fibers together without significant infiltration into the fibers. The films also have sufficient adhesiveness to maintain contact with a release layer but are not so adhesive that they do not prevent removal of the unidirectional tape with hand pressure. Preferably the total resin content of the films is from 1% to 20%, preferably 3% to 15% by weight relative to the total resin and fiber weight. At such a level, the tape is capable of being handled by a preform assembler and draped over contoured surfaces without distortion or separation of the unidirectional fibers.Type: GrantFiled: November 22, 1994Date of Patent: March 5, 1996Assignee: DOW-United Technologies Composite Products, Inc.Inventor: Martin P. Wai
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Patent number: 5399395Abstract: A multi-vane structure for incorporation in an aircraft gas turbine engine has vanes of complex geometry made of braided fibers which are continuous about the cavities defined by the vanes. These complex geometry parts are prepared by providing a plurality of removable mandrels, stacking the mandrels along a horizontal axis in a cavity end to cavity end configuration, braiding about the mandrels, cutting the mandrels adjacent the cavity end faces, side stacking the mandrels so the faces are placed in a parallel orientation and molding. Utilizing braided fibers instead of hand lay-up woven fibers eliminates seams and produces cavities having continuous fibers about the periphery thereof which substantially increases the strength and dimensional reproducibly of the part.Type: GrantFiled: November 15, 1993Date of Patent: March 21, 1995Assignee: Dow-United Technologies Composite Products Inc.Inventors: Thomas P. Forman, Rance B. Fox, George E. Sabak, Timothy A. Sands, Paul A. Vallier
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Patent number: 5296183Abstract: A method for producing a unitary part having a property enhancing coating strongly bonded to a core of either plastic or fiber reinforced composite is provided by applying the coating to a formed and shaped carrier substrate which is placed into the mold. Plastic is injected into the mold such that the plastic infiltrates the coating during molding and therefore locks the coating to the part after cure. Utilizing the present method substantially enhances the coating bond strength and reduces manufacturing costs by eliminating a post production coating step.Type: GrantFiled: August 21, 1992Date of Patent: March 22, 1994Assignee: Dow-United Technologies Composite Products, Inc.Inventors: John W. Carbone, Douglas M. Hoon
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Patent number: D547461Type: GrantFiled: January 13, 2006Date of Patent: July 24, 2007Assignee: EPOCH Composite Products, Inc.Inventors: Jonathon K. Kemnitzer, Lawrence E. Guerra
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Patent number: D341667Type: GrantFiled: April 30, 1991Date of Patent: November 23, 1993Assignee: Composite Products, Inc.Inventors: William J. Schultz, Gregg A. Laurie, Larry A. Demaree