Abstract: A method of integrally forming a bicycle front fork formed from a compound material including the steps of preparing a mold of a length greater than the front fork; forming a curved groove at a rear end of the mold; winding a blank of a front fork shape from a compound material and placing the blank into the mold; inserting an inflatable tube into the blank from a vertical tube at an upper end thereof through a forced portion on one side and round the curved groove and then through a formed portion on the other side to have the end in the vertical tube; and forming a front fork from the blank by inflation, heating and applying pressure.

Abstract: A method for joining thermoplastic resin molded products by pressing together joining surfaces of two molded products with electric resistance wire therebetween is provided, wherein the method comprising: a first step in which electric resistance wire 20 is sandwiched between the joining surfaces of two molded products which are to be joined, pressure is applied at a first predetermined pressure, and current of a predetermined value is applied for a predetermined time to the electric resistance wire, so that the resin around the electric resistance wire is melted by the thermal energy produced in the electric resistance wire while the surfaces of the two molded products that are to be joined are held at a predetermined interval; and a second step in which, following the conclusion of the first step, the current being applied to the electric resistance wire is stopped, and a second predetermined pressure is applied to attach the molten resin under pressure.

Abstract: A composite molded product has a main body molded of a base material of a thermoplastic resin and defining at least one through opening. A porous skin material is integrated with the main body by thermal fusing. At least one rib is formed on the surface of the skin material at a position corresponding to the position of at least one through opening. At least one rib is integrated with the main body through porous structure of the skin material.

Abstract: The process of forming an electret nonwoven web, the process including the steps of providing a nonwoven web, generating a DC corona discharge from an apparatus including an anode electrically configured as a parallel device, and subjecting the web to DC corona discharge to form an electret.

Abstract: A method of producing a carbon-carbon part having a filamentized composite fiber substrate is provided. A substrate having a plurality of discontinuous filamentized fibers and a binder that binds said filaments together to form a composite substrate is provided, and carbon atoms are deposited onto the filaments at a predetermined temperature so that the binder is removed completely from the filaments and replaced with carbon atoms to from a dense carbon-carbon part.

Abstract: A process for the production of a multi-chamber packaging tube of plastic material, comprising a tube body portion with a tube head thereon, and at least one separating wall accommodated in the tube body portion and the tube head. To mount the tube head to the tube body portion by means of a tool including a die and a bar as respective tool halves, the bar is loaded with a separating wall and subsequently a tube body portion or vice-versa.

Abstract: At least one mold is provided having a mold cavity and a mold gate communicating with the mold cavity, an injection nozzle for feeding molten plastic material to the injection mold having a nozzle outlet in line with the mold gate, and a thin movable valve gating arrangement positioned between the mold gate and nozzle outlet having an orifice therein permitting and shutting off flow of molten plastic from the nozzle to the mold.

Abstract: A process for reconstituting or reconstructing a composite object having a defect which affects at least its surface includes: (a) placing at least one added piece or material, the shape and dimensions of which are matched to those of the defect, in or on the defect, the piece or material including mechanically strong, continuous or staple fibers; (b) placing a polymer material in or on the defect to obtain a plastic matrix in which the fibers are distributed; (c) placing a gas-drain for draining the gases given off by the plastic matrix and a cover for extracting the gases, in succession and one on top of the other, on the added piece, which together with the rest of the object form an enclosure which is sealed with respect to the external atmosphere and circumscribes the defect and the added piece; and (d) while evacuating the sealed enclosure, heating the added piece using a radiant source, the emission from which includes infrared radiation, and placing the source with respect to the defect so as to irrad

Abstract: A composite shaft having an integral grip. The shaft comprises a plurality of plies of pre-preg composite sheet molded into a tubular shaft body. The shaft body has a grip directly molded on one end which may include a grip geometry and/or an ornamental pattern. To manufacture the shaft, plies of pre-preg may be wrapped around a bladder-covered mandrel in a predetermined manner and placed in a mold. The mold defines a cavity including, if desired, a selected grip geometry and/or ornamental design. The bladder is inflated, forcing the plies of pre-preg against the wall of the mold, and the mold is heated for a selected time to cure the plies. The grip of the shaft may be covered with a light coating material, providing a rubber-like feel.

Abstract: A core is made of a biodegradable material, reinforcing fibers and non-hardened resin are laminated on the core so as to form a fiber-reinforced composite material. Then, the fiber-reinforced composite material is hardened, and then biochemically active substances, such as microorganisms and enzymes, are brought into contact with the core so that the core is biochemically degraded and removed.

Abstract: A single piece battery jaw and method and apparatus for producing the same employs a stack molding type machine with material injection from the platens. The apparatus can effectively injection mold a one-piece jar with a straight side wall or an undercut side wall. Zero draft capability is also provided. The apparatus also includes an extraction device and core stabilizers.

Abstract: A resin mold product and a wiring method are provided. This resin mold product includes a main body formed into a pillar trim, side walls which are situated higher than wires, and wire receiving portions formed between the side walls. According to the wiring method: the wires, which have been cut to a suitable length for the front pillar, are received by the wire receiving portions; the side walls are partially melted so as to weld and secure the wires to the resin mold product; the resin mold product is mounted to the front pillar; and circuits mounted on the instrument panel and the roof are connected to each other.

Abstract: A method of producing a laminated structural molding formed from molded resin and an outer layer of facing material. The method comprises the step of initially placing the facing material in a mold. Molten resin is injected into the mold. The resin is spread throughout the mold by locating mold sections adjacent each other at a set compressive force. The partially assembled molding is then subjected to a cooling process in which the compressive force to which the molding is exposed is reduced so that the force is greater than zero but less than the compressive force used to spread the resin. The mold sections do not retract or move during the reduction in the compressive force. The cooling process is performed just before or after the completion of the spreading of the resin. In this way, the damage to the facing material of the molding is kept to a minimum.

Abstract: A method for joining thermoplastic pipes made by spiral winding a hollow profile with mainly rectangular cross section.

Abstract: A process of forming a thermal insulation layer (34) includes advancing a multifilament strand of continuous filaments (12) through a nozzle (10) to separate the filaments (16) from each other to form a continuous-filament wool (14), applying a binder to the filaments, placing a charge comprising the wool in a mold (32), and molding the charge to form an insulation layer (34). In a preferred embodiment, the charge (30) further comprises a container, such as a bag (24) formed from a poylmer film. The filaments are preferably prepared from a high-strength, high-temperature resistant glass material. The molded wool is advantageously used to manufacture products, such as catalytic converters (46) wherein the wool is used to thermally insulate the catalytic core element (48).

Abstract: A system and method of forming a carbon fiber composite material in which a series of carbon fibers are woven together and treated with a resin to form a sample or weave. The carbon fiber sample is then vacuumed, compressed and is cured to form a solid plank or board that is then cut, sanded and polished to form a finished product.

Abstract: A compression molded fixed angle carbon fiber centrifuge rotor and method for forming the centrifuge rotor are provided. My prior art technique of compression molding is utilized in which a frustum fixed angle rotor body is formed between mold parts. As before, sample tube aperture cores are clustered from the apex end of the mold in that array which duplicates the intended number, size, and angularity of the sample tubes desired in the finished rotor. The bottom boundary of the rotor mold has no longer has a substantially planar boundary; instead the bottom of the rotor mold is supplied with a series of scallops, these scallops being equal in number to the sample tube aperture tubes. The shape at the bottom boundary of the rotor is maintained to give a substantially uniform thickness between the sample tube apertures and the exterior bottom surface of the rotor. Sufficient thickness of material is maintained to resist natural load of sample within the sample tube apertures.

Abstract: A continuous process and apparatus for producing oriented plastic tube comprising the steps of extrusion, temperature conditioning, diametrical expansion and cooling, characterized by the step of inducing axial draw of the tube between first and second haul-off means located upstream of the expansion step.

Abstract: A process for producing a hollow article made of a composite material of reinforcing fibers embedded in a matrix of hot-polymerized resin includes a step in which at least one core made of a silicone elastomer is draped with at least one layer of resin-impregnated reinforcing fibers. A resultant assembly is moulded to shape the internal and external surfaces of the hollow article by simultaneous inward and outward compression of at least one resin-impregnated fiber layer caused by movement of mould walls towards each other and by thermal expansion of at least one core.

Abstract: A cushioned bicycle saddle and a method for manufacturing same are provided. The saddle includes a multiple density, cushioned surface bonded to a saddle shell which may include multiple openings. The saddle includes layer of soft, resilient gel bonded to a fabric surface. A flexible, orthotic shoe, disposed between the shell and the resilient gel, is provided in cooperation with the shell openings. The saddle may include an opening in a horn portion of the shell and the shoe may be highly resilient along the horn opening in order to prevent excessive pressure on a cyclist seated on the saddle. A method includes the steps of disposing the saddle shell having a fabric sealed thereto, into a mold having a molding surface defining a desired contour and/or pattern of embossment to be formed in the fabric. A thermoplastic gelable medium is injected between the shell and the fabric. The fabric is contoured and/or embossed by allowing the gelable medium to cool while the shell is disposed in mold.