Abstract: A system for shaping an optical fiber with various geometries while minimizing unwanted artifacts in the core of the optical fiber. The system facilitates control of sag in the region of the core that is exposed to a beam of optical energy. The sag is reduced, if not eliminated, by maintaining the cross-sectional area of the core that is exposed to the beam at thermal equilibrium.

Abstract: A multi-ribbed power transmission belt having longitudinal grooves and transverse grooves that form a plurality of cogs on the belt surface defined between adjacent transverse grooves is provided. The pitch lengths of the rows of cogs are randomized or sequenced over the entire length of the belt to reduce the noise of the belt as it travels about its associated pulleys. The ideal pitch pattern on a belt is variable, dependent upon the circumferential length of the belt. To create an optimized pitch sequence for belts of various circumferential lengths, a method of manufacture is employed wherein a portion of the pitch sequence of a shorter belt is incorporated within an optimized pitch sequence of a longer belt and both belts are manufactured from a single mold. The longer belt may contain cogs of various shapes intended to offset a range of frequencies and minimize noise generation.

Abstract: When drilling a multi layered sheet-like material, drilling is first made with pulses having energy that generates an inter-layer pull-off force smaller than the adhesion force between the layers. Then pulses with higher energy are radiated for trimming the shape of the holes, and thus through-holes having a desired shape are drilled without causing delamination of the layers.

Abstract: Molding apparatus for rapid transfer of molten resin or pitch in an infiltration molding process. The apparatus includes e.g. an extruder (4) for melting and conveying a resin or pitch and a mold (10) arranged so that resin or pitch is conveyed to a mold insert cavity (19) within the mold. The mold insert contains an internal protrusion such as a locating ring (25) for positioning a porous body (1, 18) within the mold insert cavity in a position that brings about unidirectional flow of the molten resin or pitch through the porous body. Also, rapid resin or pitch infiltration molding process that includes injecting a high melting point, high viscosity, molten resin or pitch into the mold to effect a unidirectional impregnation of a heated preform via a pressure gradient in the mold.

Abstract: A method of making a catheter balloon or other expandable medical device, and a balloon or other device formed thereby, in which at least a portion of a tubular, wrapped sheet of polymeric material is heated with laser radiation to form a fused seam extending along at least a section of the length of the tubular body. In one embodiment, the portion of the sheet heated by laser radiation is less than the entire area of the sheet, so that the fused seam is formed by heating portions of the sheet without heating sections of the sheet spaced apart from the fused seam. In one embodiment, the sheet of polymeric material comprises a polymer having a porous and preferably a node and fibril microstructure, which in one embodiment is selected from the group consisting of expanded polytetrafluoroethylene (ePTFE) and expanded ultra high molecular weight polyethylene.

Abstract: A multi-lap mold manufacturing system includes an overhead rail circuit upon which a multiple of molds transit a closed loop for a multiple of laps. The system is separated into Zones in which a particular mold operation is performed relative to which lap each of the plurality of molds has completed. At least one of the Zones is a spray Zone in which the mold is sprayed robotically. Robot utilization is extremely high as multiple spray operations occur in but a few spray Zones. Application of exceedingly expensive environmental emission control devices is at least partially mitigated by the reduced number of spray stations and the much smaller factory footprint. Consolidation of multiple spray operations into a few spray Zones also advantageously simplifies the control of chemical and ambient variables which improves production efficiencies and reduces operator dependency.

Abstract: A method of making a composite doctor blade is provided. The composite doctor blade includes multiple layers of composite material including a plurality of abrasive unidirectional fibers, in which a substantial proportion of the fibers are aligned in a direction substantially parallel to the long axis of the doctor blade. The unidirectional fibers are provided in a unidirectional fabric that includes, based on fabric weight, at least 60% by weight unidirectional fibers.

Abstract: The present invention relates to a method for fabricating a functional dental element, such as a crown. According to the invention, use is made of a three-dimensional printing technique. The major advantages of the invention are that no mold is needed anymore, which entails a considerable saving of costs, that a great accuracy is achieved, and that the element can be made of different materials.

Abstract: The present invention relates to methods and apparatus of molding composite parts by liquid resin infusion. The invention involves the creation of temporary resin distribution channels on the surface of a preform to aid in the distribution of resin during infusion. In general, these methods are improvements over the art because the molds are cheaper to make, the parts produced are of higher quality, minimal waste is produced and the time to infiltrate the preform is reduced. Hollow tubes with moveable portions provide Channels which Assist in Resin Transfer Molding of composites (CARTM).

Abstract: A method is provided for producing a molded part that is deep drawn from a thermoplastic foil. An outer surface of the thermoplastic foil is provided with a positive depth structure, under the effect of heat and pressure, by means of a stamping or embossing roller that has a negative depth structure. In at least one extent of a surface of the embossing roller, the negative depth structure of the roller is compressed in such surface regions thereof that effect a stretching of the foil during deep drawing. Subsequently, at least a portion of the foil is deep drawn.

Abstract: A method and a mold used with this method for manufacturing cast spray diffusers is described in which, in order to prevent an expensive reworking of important corners and edges, the molded parts are formed is such a way that mold parting planes are moved out of these critical areas. In particular, the transitional area between a rotationally symmetric swirl chamber of a spray diffuser in the narrow mouthpiece channel and the outlet edge of the mouthpiece are each placed in one-piece molded parts that abut against these adjacent molded parts outside these areas.

Abstract: A method provides for full or partial infusion of resin into three-dimensional, woven textile preforms. Resin film is placed at selected locations adjacent the preform, and the resin film may be separated from other areas of the preform using separator sheets or other materials. The preform is heated and may be vacuum-bagged to apply pressure, or may be rolled or fed through a die. The heat and pressure cause the resin to infuse into the selected areas of the preform adjacent the resin films. The amount of resin in the partial infusion is the same as is necessary to fully infuse the preform, but the resin remains localized in the selected areas until heated again at cure to cause the resin to flow throughout the preform. The method may also be used to fully infuse the preform with resin by providing sufficient temperature and time at that temperature during the initial infusion.

Abstract: A method and apparatus for bending a substantially rigid substrate (22) having first and second portions (28, 30) interconnected by a bend region (32). The apparatus comprises first and second heated die members (60, 80). The first heated die member (60) has a longitudinal body portion (62) and an outer edge portion (64) that extends along the longitudinal body portion (62) and is substantially rounded. The second heated die member (80) has a longitudinal body portion (82) and a groove (84) that extends along the longitudinal body portion (82). The first and second heated die members (60, 80) are configured to contact the substrate (22) and are capable of bending the substrate (22) in the bend region (32) when the outer edge portion (64) of the first heated die member (60) slides into the groove (84) of the second heated die member (80). There is also a method for bending the substantially rigid substrate (22).

Abstract: A fiber reinforced composite article comprising a matrix and reinforcing fibers, and different operating temperature and stress combinations each across opposed surfaces and through the matrix, is made by first measuring each of the combinations. Then discrete regions, each extending completely through the surfaces and the matrix, are selected for each combination. Reinforcing fibers with strength greater than the stress in a selected region are disposed in each selected region, the strengths being different between regions responsive to the different measured combinations.

Abstract: An apparatus for making crayons is provided. The apparatus includes a base that houses a heating component, a melt pan disposed to absorb heat from the heating component, a mold, and a cover. The melt pan receives crayon material and contains it as the heating component increases the temperature, causing the crayon material to liquefy. The liquefied crayon material can then be drained by the user of the device, into a mold with crayon-shaped cavities. A cover prevents access to the melt pan and the mold during particular operating conditions of the apparatus.

Abstract: A method of forming a unitary, composite structural member, and a member formed in accordance with the process. The process involves stitching a plurality of warp knit panel sections together to generally form a plurality of independent panel sections. The sections are placed within the dies of a molding tool such that a rib portion of each section aligns. Inflatable bladders are then slipped into voids formed in between the various panel sections of the assembly. The bladders are inflated to hold with one another. Resin is then infused into the panels that make up the assembly. The assembly is then cured. When the panels are removed from the molding tool a unitary, complexly shaped, composite structural member is formed.

Abstract: A multi-lap mold manufacturing system includes an overhead rail circuit upon which a multiple of molds transit a closed loop for a multiple of laps. The system is separated into Zones in which a particular mold operation is performed relative to which lap each of the plurality of molds has completed. At least one of the Zones is a spray Zone in which the mold is sprayed robotically. Robot utilization is extremely high as multiple spray operations occur in but a few spray Zones. Application of exceedingly expensive environmental emission control devices is at least partially mitigated by the reduced number of spray stations and the much smaller factory footprint. Consolidation of multiple spray operations into a few spray Zones also advantageously simplifies the control of chemical and ambient variables which improves production efficiencies and reduces operator dependency.

Abstract: A method is disclosed for reinforcement of thin wall hollow thermoplastic storage vessels with one or more wraps of continuous fibers. This method requires thermal bonding between the reinforcement fibers and the outer surface of the thermoplastic storage vessel while the interior cavity of the storage vessel is being pressurized. The fiber wraps can also be oriented in spatial directions further resisting internal stress on the storage vessel walls when put in service.

Abstract: A method of manufacturing a one piece, composite, hockey stick in an autoclave. A mandrel is provided which has a non uniform cross section. Pre-preg flags are wrapped around the mandrel. Provision is made so that when the wrapped mandrel is inserted in a pressure application tube, a portion of the wrapped mandrel is separated from the pressure application tube by one or more spacers. Pressure is then applied to the pressure application tube which in turn applies the pressure to the spacers. The spacers then apply the pressure to the wrapped mandrel to compact the pre-preg on the wrapped mandrel. Next the spacers are removed and the pre-preg is cured. Finally, a blade is formed around the pre-preg flag.

Abstract: The invention relates to a method for manufacturing a thin-walled article, wherein a single- or multi-component, essentially polymer-based material (1), such as plastics, elastomers, and/or the like, is sprayed in an elecrical field (E) in an electrically charged state. The thin-walled article is manufactured in the electrical field (E) by spraying (II) an electrically charged material into the contact with a mould (2) set at an electric potential, after which spraying cycle (II) the article is, at least in terms of its appearance, immediately a finished product after its demoulding/releasing from the mould (2). The invention relates also to an apparatus operating in accordance with the method.