Abstract: Methods for the manufacture of reinforcing preforms for structural composite products. Minimum contact eyelets reduce friction in the supply provide chopped reinforcing materials to both of said first and second mold members, and spraying said chopped reinforcing materials into both of said first and second mold members.

Abstract: A fiber composite structural component such as a fitting, bracket, mounting or the like is produced by applying fiber material such as fiber threads or fiber yarns in an automatic circular weaving operation to a core that has at least two sections, to form a fiber material body (6). One core section is removed from the fiber material body when the weaving is completed. The body is then deformed in a mold that has the contour of the finished structural component with at least one mold core section still in the fiber material body. The deformed configuration of the structural component is then impregnated in an RTM device with a resin and hardener followed by curing. Reinforcements may be inserted or secured to the fiber material body prior to the impregnated and curing step.

Abstract: A mixture of carbon-containing fibers, such as mesophase or isotropic pitch fibers, a suitable matrix material, such as a milled pitch is compressed while resistively heating the mixture to form a carbonized composite material. Preferably, the carbonized material has a density of at least about 1.30 g/cm3. Preferably, the composite material is formed in less than ten minutes. This is a significantly shorter time than for conventional processes, which typically take several days and achieve a lower density material. A treating component may be impregnated into the composite. Consequently, carbon composite materials having final densities of about 1.6-1.8 g/cm3 or higher are readily achieved with one or two infiltration cycles using a pitch or other carbonaceous material to fill voids in the composite and rebaking.

Abstract: The inventive method concerns a process of transferring resin into reinforcing material used in the manufacture of composite articles. A first step in the method involves positioning at least one layer of the reinforcing material on the surface of an open mold. Subsequently, a sealant layer is applied in liquid form over the reinforcing material to create an airtight chamber encapsulating the reinforcing material between the sealant layer and the mold. After the sealant layer is allowed to cure, resin is drawn through the reinforcing material.

Abstract: A fabric-less part and a method of making same are disclosed. The fabric-less part may include a flexible polyurethane foam body, a high-density polyurethane foam backing layer bonded to the foam body, and a polyurethane elastomer skin bonded to the backing layer. Alternatively, the backing layer may be eliminated and the polyurethane elastomer skin is directly bonded to the flexible polyurethane foam body. The fabric-less part may be an automotive interior part such as a pillar trim, headrest, trim panel, instrument panel, door panel, armrest, or part of an automotive seat such as a seat cushion.

Abstract: A cured resin and fiber part generally can be manufactured by providing a mold that defines a cavity having at least one shape-defining surface. An in-mold paint sheet having a bonding side and a finish side can be positioned in the cavity of the mold such that the finish side of the in-mold paint sheet is positioned adjacent to the shape-defining surface of the mold. A mixture of a thermoset resin and a plurality of reinforcing fibers are then introduced into the cavity of the mold such that the resin and fiber mixture contacts the bonding side of the in-mold paint sheet. The in-mold paint sheet and resin and fiber mixture are then compressed in the mold while being heated causing the resin and fiber mixture to be cured and bonded to the in-mold paint sheet resulting in a part having the finish side of the in-mold paint sheet as a finished surface of the part.

Abstract: A process for forming a cushion layer of a preselected thickness on an inside of a prosthetic liner body is provided and includes the steps of introducing the liner body into a mold cavity; disposing a sufficient amount of cushioning material into the inside of the liner and directing a mandrel into the inside of the liner body. The driving action of the mandrel causes the cushioning material to be dispersed between the mandrel and the liner body, thereby forming the cushioning layer of preselected thickness.

Abstract: The present invention relates to medical vascular catheters adapted to be inserted into a blood vessel from an incision through the skin of a patient for introducing other devices or fluids for diagnostic or therapeutic purposes, and particularly to an improved distal soft tip or segment attachment with a relatively stiff proximal catheter shaft. A tubular sleeve is bonded through the application of pressure and heat to a distal portion of the catheter shaft and a proximal portion of the distal segment of soft distal tip bridging the attachment junction. In the preferred method, the catheter shaft distal end is aligned with the distal segment or soft tip proximal end and the sleeve is fitted over the attachment junction. A heat shrink tube is fitted over the sleeve and adjoining portions of the catheter shaft and the distal segment or distal soft tip and heat is applied.

Abstract: A method of manufacturing a honeycomb structure and a through hole forming device used in the manufacture of the honeycomb structure are provided, in which the step of closing a part of the cell ends at an end surface of the honeycomb structure is rationalized. In closing a part of the cell ends (82) at the end surface (861) of a honeycomb structure body (86), a film (2) is attached to the end surface (861) of the honeycomb structure body (86) in such a manner as to cover the cell ends (82). The portion of the film (2) located at the cell ends (82) to be closed is thermally melted or burnt off thereby to form through holes (20). The end surface (861) is dipped in a slurry containing an end surface closing material, so that the slurry is caused to enter the cell ends (82) by way of the through holes (20). After that, the slurry is hardened while at the same time removing the resin film (2).

Abstract: Processes for fabricating a customized, three-dimensional, bioerodable, polymeric prosthetic implant are provided. In a highly preferred embodiment, the prosthetic implant has a porous network. The method employs a sterolithography instrument, a solution comprising chains of one or more photocurable, bioerodable polymers and a photoinitiator, and a three-dimensional CAD image. In a highly preferred embodiment, the solution comprises poly (propylene) fumarate (PPF) and a solvent for controlling the viscosity of the solution. During the fabrication process, the solution is placed in a container in the stereolithography instrument. The container also holds a movable build platen for supporting each of the covalently bonded layers of the polymeric prosthetic implant that are formed when successive layers of the solution are exposed to UV light energy.

Abstract: In a method for producing fiber-reinforced plastic components made of dry fiber composite preforms by an injection method for injecting matrix material, the arrangement of the fiber composite preform on one surface of the preform resulting in a flow promoting device, on a tool, creates a first space by a gas-permeable and matrix-material-impermeable membrane surrounding the preforms. Formation of a second space arranged between the first space and the surroundings by a foil, which is impermeable to gaseous material and matrix material, is provided, with removal by suction, of air from the second space resulting in matrix material being sucked from a reservoir into the evacuated first space and with the flow promoting device causing distribution of the matrix material above the surface of the preform facing the flow promoting device, thus causing the matrix material to penetrate the preform vertically.

Abstract: A method of fabricating a panel of composite material. The panel includes two outside skins and stringers attached inside of the two outside skins for reinforcing the two outside skins. A plurality of stringers for reinforcing outside skins is formed from dry preformed fibers and are disposed at a predetermined interval.

Abstract: In the invention, an oscillating horn of an ultrasonic processing apparatus is moved along a planned process line and along the side of a rear face of a resin skin which is fixedly held so that the front face is closely in contact with a flat face of a surface table, whereby a resin for the skin is sequentially fused by ultrasonic vibration, and a fused resin is removed to sides to process a linear groove. Therefore, the linear groove having a reproducible constant breakage resistance can be efficiently processed on the side of the rear face of the skin, without applying any damage to a design face, and with reduced power consumption and simple control.

Abstract: A method of manufacturing a honeycomb structure, the method comprising the steps of forming staggered cells through the entire thickness of a fiber fabric, causing loosely held pegs to penetrate into respective ones of the cells, each peg having a cross-section of size smaller than that of the corresponding cell and being made of a material that is suitable for expanding; expanding the pegs so that they fill the cells and exert pressure on the inside faces of the cells; and shrinking the pegs and then withdrawing them.

Abstract: A process for forming a multilayer composite insulator includes: (a) forming an insulator precursor by orienting an insulation insert in a desired location between a first facing layer of and a layer of a polymer based blanket material; (b) closing the insulator precursor in a molding press; (c) heating the insulator precursor in the molding press to a temperature sufficiently high to soften polymer binding fiber in the polymer based blanket material and cause reshaping; and (d) cooling the insulator precursor in the molding press so as to set the insulator precursor in its molded shape and complete formation of the insulator. Other relates processes are also disclosed.

Abstract: A method of controlling thermal loading of an electronic component material during ablation thereof provides a first laser light beam 42 at a certain power density and fluence and uses the first laser light beam to remove a portion of a first side 47 of the material 36. A second laser light beam 44 is provided at a certain power density and fluence and the second laser light beam is used to remove a portion of a side 49 of the material opposing the first side thereof substantially simultaneously as the portion of the first side is being removed.

Abstract: In order to provide a process for the production of a component consisting of a fiber reinforced material, with which liquid resin is supplied to a semifinished fiber article by way of application by vacuum pressure, it is provided for a heat curing resin to be used as resin and for application by vacuum pressure and temperature to be controlled such that in relation to the liquid resin the boiling point curve of the resin is not exceeded.

Abstract: Method of forming a fiber web (210) intended for use in absorbent products, such as sanitary towels, by air-laying fibers. Separate air flows containing fibers are fed to a number n of different mat-forming wheels (160, 170, 180), where n is a whole number which is at least 2. Separate web layers (161, 171, 181) are formed on each mat-forming wheel. The fiber web (210) is formed by virtue of said web layers being combined downstream of the mat-forming wheels to form a common fiber web which is imparted very great manufacturing accuracy by virtue of the manufacturing method. The manufacturing speed and thus the web speed can be very high, and the desired manufacturing accuracy at the web speed concerned is achieved by selecting a sufficiently great number n of mat-forming wheels. The invention also relates to a fiber web manufactured according to the method.

Abstract: A method for forming composite materials is presented, including providing a composite charge wider than a first surface of a mandrel, and positioning the composite charge across the first surface of the mandrel. The portion of the composite charge overhanging the first surface of the mandrel is supported and urged against the mandrel while supporting the unbent portion of the composite charge substantially parallel to the first surface of the mandrel. The invention also provides a system, using a compression mold of forming bladders and heater plates, to form a composite charge over a mandrel, while supporting the unbent portions of the composite charge during forming substantially parallel to the upper surface of the mandrel. The present invention minimizes the shear zone where plies in the composite laminate charge slide past one another during the forming process reducing or eliminating out-of-plane fiber buckling.

Abstract: Vacuum assisted molding apparatus provides reliable sealing about the mold cavity while minimizing the area of the plant floor space occupied by the mold. The apparatus includes an upper die, a lower die, a vacuum source, and a sealing assembly. The upper die includes a generally horizontal molding surface and vertically extending sides. The lower die includes a generally horizontal molding surface cooperating with the upper die to form a mold cavity. The sealing assembly is operable to create a vacuum surrounding the mold cavity.