Abstract: Two co-reactive resin stream are mixed immediately adjacent the entrance of an impregnation die used to make products by the pultrusion process. The mixing occurs immediately adjacent the fibers as they are pulled into the central duct opening of the die. The resin streams are delivered to the entrance of the impregnation die by use of a resin feed head positioned at the inlet of the impregnation die. An ultrasonic driver coupled to the resin feed head vibrates and agitates the resin streams impinging the fibers so as to thoroughly wet the fiber bundle prior to its passage through the die.

Abstract: An improved method for manufacturing a laminate wherein the edges of a deformable surface layer, such as cloth or carpet, are folded under and releasably secured to the undersurface of the deformable surface layer. The deformable surface layer is then placed into a mold unit and the securement between the folded edge and the undersurface of the deformable surface layer is released either prior to or during the injection of a plastic material for forming a plastic support layer. The method produces a laminate including a deformable surface layer having edges which are folded under and totally bonded to the plastic support layer. The bonded edges improve the securement between the deformable surface layer and the plastic support layer and give the laminate a "finished" appearance without tacks or staples.

Abstract: A process for forming a plurality of interfitting sculptured pieces of irregular fanciful shapes having complementary curved surfaces. The pieces are formed of urethane plastic or other appropriate molded material.

Abstract: Disclosed is a synthetic resin feeding apparatus including an extruder having an extrusion plate with an extrusion opening formed therein and a cutting tool for cutting molten synthetic resin extruded from the extrusion opening. The extrusion plate is formed to have a tapered portion. The extrusion opening opens to the front end surface of the tapered portion.

Abstract: A system for coating articles by the use of electrostatic attraction of ionized particles which are subsequently cured. The system includes a pair of carriers for jointly carrying each article through the system, from application of the particles to the article through curing of the particles on the article. Each carrier is capable of carrying the article independently of the other. After deposition of the particles on the article the article and the carriers are conveyed through a cleaning station wherein one of the carriers is moved out of carrying engagement with the article and cleaned while the article supported by the other carrier. The other carrier is then moved out of supporting engagement with the article and cleaned while the article is supported by the first carrier.

Abstract: An apparatus is disclosed for rapidly laying up and curing thick complex shaped resin matrix composites connected to a rotatable and alterable male mold to wrap a plurality of continuous and intermittent layers of uncured laminate around the male mold when said mold is in a closed position; moving the male mold into a female mold and thereafter severing all layers on the male mold and articulate the male mold to an open position which shapes the upper regions of the composite and thereafter transferring the resin matrix composite to a female mold which shapes the composite in a desired configuration and thereafter heat cures the composite lay-up while being subjected to a vacuum. A second embodiment of the invention uses a non-rotatable male mold.

Abstract: A method for minimizing surface carbide formation during box annealing of DQSK steels includes as a first step treating the surface of an aluminum-killed steel suitable for production of DQSK product with an aqueous solution containing about 0.1 to 1.0 moles of phosphate ion per liter. This treatment is applied to provide a surface phosphorus concentration on the steel of at least about 10 mg P/ft.sup.2. The treated steel is then box annealed at a temperature of at least about 1250.degree. F. in a hydrogen-rich atmosphere which is non-oxidizing to steel.

Abstract: A method and apparatus for vacuum bag molding of composite materials which eliminates the need for a porous release sheet. Prepregs are placed on a forming tool and overlayed with at least one sheet of nonporous material and a breather sheet and then enclosed within an impermeable membrane. The volume enclosed by the membrane is evacuated, the resin in the prepregs is outgassed, and the prepregs are coalesced to mold the prepregs to the shape of the forming tool. After curing the resin, the temperature is reduced and the resultant article is removed from the forming tool.

Abstract: A process for continuously and progressively forming components from fiber-containing composite material workpieces having a deformable matrix introduces transverse bends into a workpiece that moves through the apparatus in a longitudinal or travel direction. Transverse bending of the composite material is accomplished in a kinematically admissible manner to avoid misalignment or failure of the composite material. A net bending deformation is introduced at a free transverse edge as the composite workpiece moves in a longitudinal direction, by pairs of compound roller elements between which the workpiece passes as it moves through the apparatus. The net deformation introduced at the free transverse edge is moved and distributed through the composite material workpiece during successive passes through the forming machinery, to form the final shaped component.

Abstract: A method of making an electrical contact to a metal on which an electrically insulating native oxide is formed includes applying atoms or ions to the native oxide, heating the metal and oxide to a temperature and for a time effective to make the oxide, where the atoms and/or ions have been applied, electrically conducting and in electrical communication with the metal. The invention may be employed to establish electrical contacts with native oxides on aluminum, molybdenum, niobium, tantalum, titanium, tungsten, and zirconium. The atoms and ions include aluminum, antimony, arsenic, boron, gallium, indium, phosphorus, and silicon. An aqueous solution of boric acid and trisodium phosphate may be applied to establish electrically conductive regions in an oxide on niobium, tantalum, titanium, and stainless steel after heat treatment. Brushing with palladium wires mechanically applies palladium atoms to tantalum oxide to establish electrical contact to the tantalum after heat treatment.

Abstract: An apparatus for forming multiple layer preforms wherein the various layers may be varied as to number, material, thickness and position in the preform by controlling the injection of the specific materials as to timing, quantity and rate of delivery. Most specifically, a featured aspect is the ability to simultaneously deliver to an injection nozzle and through such injection nozzle into a preform mold cavity two or more molten plastic materials simultaneously. This is possible by way of a multiple gate nozzle and a plurality of separately operable metering pots all controlled by way of a timing device. The timing device may also control the rate of the dispensing an individual material from each of the metering pots.

Abstract: A winding device having a rotational axis and two side walls arranged perpendicular to the rotational axis. Each side wall is provided with two slits extending from the middle portion to both extreme ends of the side wall. A supply of bolts is arranged to the winding device whereby the bolts have a smaller diameter than the width of the slits and a greater length than the distance between the two side walls.

Abstract: A bumper assembly having a fascia and a support member including an integral core made of a fiber reinforced composite resin adapted to be connected to a vehicle frame. The integral core has a back plate portion adapted to extend vertically of the front end of a vehicle and a plurality of reinforcing boxes formed with the back plate and extending forwardly and transversely. One of the reinforcing boxes is located at the top of the back plate and another is located at the bottom of the back plate. A cavity between the back plate and the fascia is filled with an energy absorbent material.

Abstract: A method of injection molding and a mold for the forming of a thin walled fabric reinforced elastomeric diaphragm. According to the method, a thin, precut, preformed sheet of fabric material is placed within a suitable injection mold cavity. Subsequently, a high molecular weight elastomer is injected into the mold cavity in a controlled manner to prevent migration or weave distortion of the fabric material.

Abstract: A hard roll is produced by a process utilizing the steps of winding a fiber material impregnated with a thermosetting resin around the outer peripheral surface of a metal roll core to form a fiber-reinforced lower winding layer, then injecting a thermosetting synthetic resin material into a mold of predetermined size and curing the material at a specified temperature to form an outer layer hollow cylinder separately from the first step. The next stepsave fitting the outer layer cylinder around the roll core covered with the winding layer, and injecting an adhesive of low viscosity into an annular clearance between the winding layer and the cylinder and then curing the adhesive at a specified temperature to bond the winding layer to the cylinder with the layer of adhesive.

Abstract: Apparatus for pultruding thermoplastic, resin-impregnated, fibrous substructures heats the substructures to a temperature just below the melting temperature of the resin. The heated substructures are then simultaneously pulled through a passage to conform them to a desired cross section. At least a portion of the perimeter of this passage is formed by a wave guide. The wave guide is vibrated at ultrasonic frequency in a predetermined direction so as to direct the ultrasonic vibration into the substructures within the passage. The application of the ultrasonic vibration stimulates the flow of the resin in the heated substructures. Pressure is applied to the flowing substructures within the passage to consolidate them into an integral structure conforming to the chosen profile. The ultrasonic vibration at low power input does result in some heat transfer to the profile, but the flow rates of the resin exemplify an increase in flow far greater than expected in relation to the temperature increase.

Abstract: A dual charge compression molding method in which a first charge of a plastic material that will at least constitute the reinforcing means, i.e., the ribs and/or bosses, is first placed in the mold and compressed, the mold is then opened and a second charge of the plastic material is placed in the mold to constitute the flat or panel portion of the panel part after compression. A plastic part having a perfect appearance surface without sink mark defects can be produced.

Abstract: Compositions and method for applying a coating to a metallic surface characterized by the presence of tellurium and/or selenium.

Abstract: A method of protecting glass fiber reinforced products from the effects of weathering by applying a polymeric resin overlay to the product in mold. Conventional waxing of molds is eliminated. The mold is prepared by applying a layer of a lecithin solution, and the overlay is applied thereafter. A layer of gel coat is then applied to the overlay, the gel coat is reinforced and the overlay-protected product is demolded. The invention also includes a method for making an overlay-protected synthetic marble product.

Abstract: An apparatus for molding hollow composite articles having a plurality of internal webs. A mandrel assembly apparatus includes slidable sidewall members, an inflatable pressure membrane surrounding the length of the slidable sidewall members and actuator means mounted on the interior of the sidewall members for lateral displacement thereof together with the inflatable membrane. Adjacent mandrel assemblies accurately position the internal webs of the composite article mechanically, while the inflatable membranes serve to compact the web laminates. The expandable sidewall members also prevent bridging or tearing of the pressure membrane associated with the formation of inner corner radii.