Abstract: A starter block and a shingle are utilized to form courses that may be positioned in overlapping fashion on a roof to form a roofing covering system. The particular design of the starter block and shingle result in a roofing product that provides increased durability over previous designs. The starter block may be formed with top and bottom surfaces, opposite side surfaces with tapering heights, and a front surface having a greater height than a back surface of the starter block. When the starter block is coupled to a roof deck, a semi-rigid shingle having a generally planar bottom surface may be placed upon the starter block so that a portion of the shingle extends off of the starter block over the back surface thereof and onto the roof deck to facilitate contact between the shingle and the roof deck at a location more proximal to the starter block back surface than if the same back surface had the same height as the front surface.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: There is provided by the present invention a compression molding tool for producing apertures of a desired configuration in preselected locations in a compression molded article and a method for producing the apertures. The tool has first and second relatively movable tool halves each supporting a mold section. The mold section associated with the second tool half includes a movable portion that is relatively movable with respect to the second tool half. The first tool half is moved relative to the second tool half until the first and second mold sections engage each other to form a mold cavity therebetween. Devices for creating apertures are included on at least one of the mold sections and are extended into appropriately configured receptacles in the other mold section after the mold sections are engaged, but before molding material is forced by compression into the mold cavity.

Abstract: Multiple extruder apparatus for compounding thermoplastic resin and reinforcing fibers incorporates a resin extruder in which thermoplastic resin pellets are melted and a compounding extruder in which the molten thermoplastic resin is mixed in intimate contact with long reinforcing fibers of at least one inch in length. The melted thermoplastic resin is introduced into the compounding extruder at a point downstream of the inlet point for the reinforcing fibers, so that the fibers are mechanically worked and heated before coming into contact with heated, molten thermoplastic resin. The extrudate from the compounding extruder consists of a homogeneous, molten mass of thermoplastic resin having discrete lengths of fibers randomly dispersed therein. This hot mixture may be fed directly into preform-making equipment to produce a measured preform of desired size, weight, and shape. The preform may then be fed directly into a compression molding machine.