Abstract: A method of producing an orthotic brace or prosthetic device comprising the steps of creating an anatomical mold or cast of that portion of the patient's anatomy upon which the orthotic brace or prosthetic device is to be applied, applying at least one layer of epoxy resin over at least a portion of the anatomical mold, applying at least one layer of carbon graphite fabric on at least a portion of the layer of epoxy resin, placing the anatomical mold with the epoxy resin and carbon graphite fabric in an enclosure having an interior, heating the interior of the enclosure to melt the epoxy resin and reducing the pressure in the interior of the enclosure causing the melted epoxy resin to impregnate the carbon graphite fabric, and allowing the melted epoxy resin to harden in the carbon graphite fabric forming the orthotic brace or prosthetic device.

Abstract: Method and apparatus for controlling the stacking height of stackable products during compression molding off stops includes slides that are movable into and out of an end of blind pockets in a compression mold in which the stack height surfaces are formed during the molding cycle. The slides are held in a retracted position until after the mold is closed and the molding compound flows to the shape of the molding cavity inside the mold including the blind pockets. Then the slides are extended into the ends of the respective blind pockets the same distance to compress the molding compound and obtain the desired height of the stack height surfaces formed by the blind pockets.

Abstract: A molding device is provided with a holding portion for clamping the end of an extruded portion, and a cavity for forming a molded portion. The holding portion has holding cores to come in contact with the end of the extruded portion, and at least a part of the holding cores is formed by a material with a low thermal conductivity. Thus, the molding method of a weather strip includes, clamping the end of the extruded portion by the holding portions, then, ejecting or injecting a rubber material for molding the molded portion in the cavity, and then, molding the rubber by vulcanization.

Abstract: A process for manufacturing a compressed gas tank that includes a combination of an injection molding process and a rotomolding process. In a first step, a boss to be positioned in the opening of an outer structural layer of the tank is provided and a thin portion of the liner is injection molded to the boss so that a channel within the boss is filled with the liner material to increase the seal integrity between the boss and the liner. Once the liner material is hardened, the surface of the injection molding liner portion is cleaned. Next, a rotomolding process is performed to mold the remaining portion of the liner to the boss. During the rotomolding process, the injection molded portion of the liner melts to be part of the liner made during the rotomolding process.

Abstract: A method of manufacturing a fuel cell bipolar plate that improves dimensional accuracy even with viscous material, eliminates the need for large-scale production equipment such as a press to make a pre-formed product, and furthermore, enables manufacturing time for the fuel cell bipolar plate to be reduced. Powdered raw material A containing electrically conductive material and resin is dropped into a filling container so that a top thereof is flat. The powdered raw material A inside the filling container is then heated to form a temporary cast B, the temporary cast B is set in a mold in which a predetermined pattern is formed, and heated and compressed to form a fuel cell bipolar plate.

Abstract: The present invention is directed generally to templates used in the creation of thin-film replicas, for example, the creation of thin films, such as carbon films, for use as specimen support in electron-beam specimen analysis. More specifically, the present invention is directed to novel reusable patterned templates, the methodology of making these reusable templates, the templates made from such methodologies, the use and reuse of these templates to make thin films of any type for any purpose, and the thin films made from these templates. A feature of the novel template of the present invention is in its employment of one or more zones of discontinuity, or undercuts, associated with the patterns transferred into the template to allow for the removal of the thin film from the template without sacrificing the structural integrity of the template to prevent at least one re-use of the template.

Abstract: The invention relates to a two-step process for transferring a pattern from a template (1) to a target surface of a substrate, by creating an intermediate flexible polymer stamp (5) from the template in a primary step, and then using the polymer stamp to make an imprint in a radiation-sensitive moldable layer on the target surface in a secondary step. In the secondary step, the process steps of pressing the polymer stamp and the substrate against each other, UV exposure of the moldable layer through the polymer stamp, and postbaking of the radiated moldable layer, are all performed at a control constant temperature, in order to eliminate damages to the pattern created in the moldable layer caused by thermal expansion effects.

Abstract: With regard to the technology of compaction by means of vacuum vibrocompression for manufacturing slabs of composite stone, the binder consists of a dispersion of colloidal silica in water and the rough-formed article resulting from the vibrocompression step, undergoes a drying step in order to remove the water present in the vibrocompacted slab. Subsequently the pores of the slab are filled with methyl methacrylate and hardening of the resin is performed by means of heating in hot water.

Abstract: A method disclosed for producing polymer-based cantilevers for use in atomic force microscopy in a batch process. The method includes forming a mold in a mold material, for example PDMS, using a master cantilever, removing the master cantilever from the mold material to reveal a mold cavity, filling the mold cavity with plastic, for example polystyrene, to form a plastic cantilever in the mold, and removing the plastic cantilever from the mold, for example using adhesive tape or flexing the mold. At least one surface of the plastic cantilever can be coated with a reflective metal, such as gold. The plastic cantilever can be functionalized for use in magnetic force microscopy by attaching a probe tip formed of magnetic metal, for example a 10 ?m nickel sphere.

Abstract: An apparatus comprising a vacuum source line, a pressurized fluid source line and an inlet circuit communicative with the vacuum source line and operatively connectable to an inlet container. The apparatus further comprises an outlet circuit communicative with the vacuum source line and operatively connectable to an outlet line. The apparatus also comprises an outer cover circuit communicative with the vacuum source line and operatively connectable to the outer cover. Further, the apparatus comprises an inlet restrictor fluid circuit in communicative with the fluid source line and adapted to control flow between the inlet vacuum container and interior. Moreover, the apparatus comprises a controller operatively connected to the inlet vacuum circuit, the outlet vacuum circuit, the outer cover vacuum circuit and the inlet restrictor fluid circuit for controlling operation of the inlet vacuum circuit, the outlet vacuum circuit, the outer cover vacuum circuit and the inlet restrictor fluid circuit, respectively.

Abstract: The invention concerns an installation for producing a nonwoven fabric comprising a spun bond lathe depositing a web of filaments on a first conveyor, the mat being consolidated on a first mobile element by entangling means. The invention is characterized in that it comprises means for passing, without any change in ratio, the mat of filaments on a first mobile element whereon the mat is consolidated by hydro-entangling means.

Abstract: This invention relates to a method of embossing a cured silicone resin thermoset substrate to imprint patterns onto the substrate from a master mold comprising (i) stacking a master mold with a cured silicone resin thermoset substrate such that the surface of the master mold containing a feature is facing the silicone resin substrate; (ii) applying pressure to the product of (i) in a press at a temperature slightly higher than the Tg of the silicone resin but lower than the softening point of the master mold; (iii) cooling the product of (ii) and maintaining the pressure on the mold; and (iv) releasing the substrate whereby the feature is imprinted on the silicone resin substrate. Cured silicone resin thermoset substrates offer advantages over the organic thermoplastics in terms of hot embossing lithography by offering a very smooth surface which promotes high fidelity of replication in the micrometer and manometer domain, and requiring no release agent for demolding.

Abstract: A method for fabricating structural building blocks having a cured binding material dispersed within block forming media thereof comprises a plurality of operations. An operation is performed for depositing a volume of block-forming media within a media receiving cavity of block forming equipment. The block-forming media includes a curable binding material dispersed therein and curing of the curable binding material is caused by contact with a prescribed activation material. After or in conjunction with depositing the volume of block-forming media, an operation is performed for depositing the prescribed activation material into the media receiving cavity. Such depositing of the prescribed activation material causing at least a portion of the prescribed activation material to be dispersed within the volume of the block-forming media.

Abstract: A net shaped latex vacuum bag as used in the fabrication of composite structural parts having complex shapes. Liquid latex is first allowed to air dry in the form of a thin flat, flexible sheet. The latex sheet is then vacuum formed over a tool having the complex shape of the part to be fabricated and assumes the shape and configuration of the tool's outer surface. The latex sheet is then rapidly cured at an elevated temperature, so as to permanently assume the part's shape for subsequent use in forming composite structural parts of the same complex shape. In one embodiment, the latex sheet may be formed on the tool by dipping the tool in liquid latex, allowing the latex coating to dry, and cutting the dry latex coating to permit separation of the tool from the latex coating which is then used in composite part fabrication.

Abstract: A method and apparatus for simultaneously polishing the inner and outer surfaces of an unpolished polymeric stent using a heat process. The unpolished stent can be mounted, for example, on a “spiral-mandrel,” a tubular helical structure with gaps in between a series of coils of the structure. Heat from a heat source can then applied to the spiral-mandrel at a range between the glass transition temperature and melting temperature of the polymer of the stent.

Abstract: According to the invention, a micro-structured element is manufactured by replicating/shaping (molding or embossing or the like) a 3D-structure in a preliminary product using an replication tool (1). The replication tool comprises a spacer portion (1c) protruding from a replication surface (1a). The replica (the micro-structured element, for example the micro-optical element or micro-optical element component) may be made of epoxy, which is cured—for example UV cured—while the replication tool is still in place. The replication process may be an embossing process, where the deformable or viscous or liquid component of the preliminary product to be shaped is placed on a surface and then the replication tool is pressed against this surface. As an alternative, the replication process may be a molding process.

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: A compression molding machine includes a wheel mounted for rotation around a horizontal axis and a plurality of angularly spaced molds disposed around the wheel. Each of the molds includes a first mold segment and a second mold segment disposed radially outwardly of the first mold segment. Each of the second mold segments is movable radially with respect to the associated first mold segment between a radially inner closed position with the first mold segment for compression molding a plastic article, and a radially outer open position spaced from the associated first mold segment for removing a molded article from the mold and placing a mold charge into the mold.

Abstract: Process of manufacturing carbon-carbon composite preform by: (i.) arranging batch of carbon fiber preforms in infiltration vessel; (ii.) flooding vessel with hot liquid phase pitch at atmospheric pressure in inert atmosphere; (iii.) raising pressure in infiltration vessel to elevated pressure, and then slowly lowering pressure; and (iv.) repeating step (iii.). An apparatus that may be used is a heated infiltration vessel capable of operating at pressures above 100 psi, possible equipped with means to circulate heated pitch inside the vessel, in order to facilitate heat transfer into the carbon fiber preforms being infiltrated by the pitch. The need for a vacuum pump is eliminated, and the time spent heating the preform is substantially reduced. Instead of vacuum, cycled high pressure is employed to infiltrate carbon fiber preforms with pitch. The use of preheated pitch as a heat transfer agent avoids the slow transfer of heat into the preform prior to infiltration.

Abstract: There are provided apparatuses and related methods for forming sheets. The formed sheets can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic, which can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. The apparatus includes a heater for heating the sheet to a processing temperature and a structure for configuring the sheet to a desired shape using one or more rollers, shapers, longitudinal members, and/or support members.