Abstract: A cartridge for storing and transporting fiber-bundle-based preform charges includes a plurality of cells arranged within the housing, wherein each cell is physically adapted to receive a preform charge and prevent it from moving therein as the cartridge is transported. In some embodiments, the cartridge and preform charges it conveys are serialized.

Abstract: A preform-charge fixture creates a preform charge, which is a partially consolidated assemblage of preforms that can be efficiently transferred to a mold to create a finished part in a molding process, such as compression molding. In the illustrative embodiment, the preform-charge fixture includes peripheral cleats that are movable towards a central cleat to create a small gap therebetween that receives and constrains preforms in a desired position. The fixture also includes clamps, which are operable to engage an uppermost layer of preforms in the gap and apply a slight amount of downward pressure thereto to assure that the preforms are properly seated. The fixture also accommodates an energy source that heats the preforms so that, in conjunction with downforce applied by the clamps and/or gravity, the preforms can be tacked together, forming the preform charge.

Abstract: A preformer capable of simultaneously forming plural preforms includes a forming surface and source of heat. The forming surface includes guides to keep fiber bundles, the nascent form of the preforms, spaced apart and to maintain their cross-sectional dimension. In some embodiments, the preformer further includes a source of energy, and in some embodiments, the preformer includes a source of energy and a cooling source. A method for forming preforms is also disclosed.

Abstract: A method for designing fiber-composite parts in which part performance and manufacturing efficiency can be traded-off against one another to provide an “optimized” design for a desired use case. In some embodiments, the method involves generating an idealized fiber map, wherein the orientation of fibers throughout the prospective part align with the anticipated load conditions throughout the part, and then modifying the idealized fiber map by various fabrication constraints to generate a process-compensated preform map.

Abstract: A method for forming a composite part involves forming a layup comprising (a) preforms/flat form-factor feedstock, either of which includes a plurality of fibers and a matrix precursor, and (b) a differential-melt polymer. The matrix precursor and the differential-melt polymer differ as to at least one of thermal properties and rheological properties. The layup is subjected to controlled application of heat and pressure to melt the matrix precursor and differential-melt polymer. The polymers are then cooled to form a composite part that displays properties attributable to all the constituents. As a function of a variety of factors, the resulting part can be homogenous or heterogenous, and the properties can be localized or global throughout the part.

Abstract: Fiber-reinforced composite parts include select portions containing a plurality of co-aligned fiber. The parts are fabricated by placing substantially preforms into a mold cavity to form a layup, and compression molding the layup to consolidate the preforms to provide a fiber-reinforced composite part. Different sections of the part can be derived from preforms having different shapes and different compositions.

Abstract: A method for designing fiber-composite parts in which part performance and manufacturing efficiency can be traded-off against one another to provide an “optimized” design for a desired use case. In some embodiments, the method involves generating an idealized fiber map, wherein the orientation of fibers throughout the prospective part align with the anticipated load conditions throughout the part, and then modifying the idealized fiber map by various fabrication constraints to generate a process-compensated preform map.

Abstract: An ultrasonic manipulator for processing three-dimensional composite preforms is provided, including at least one end effector, the end effector having an ultrasonic cutting device, an ultrasonic machining device, an ultrasonic inspecting device, and an ultrasonic bonding device. A method for creating three-dimensional preforms for use in molding composite parts is also provided, and includes the steps of grasping a preform/towpreg, inspecting the composite object using ultrasound, cutting a preform from the composite object using ultrasound, and at least some of the steps of shaping the preform using ultrasound, machining the preform using ultrasound, assembling a plurality of preforms, bonding the assembled preforms together to create a preform charge, and placing the preform charge in an injection mold.

Abstract: Rib-and-sheet structures include a rib comprising continuous, aligned fibers. The rib is fabricated via compression molding from continuous, aligned fiber, thereby providing an aligned, continuously reinforced rib. In one embodiment, rib-and-sheet structures are produced in a two-step compression-molding process, wherein a near net-shape rib is molded, in a first mold, from fiber-bundle based preforms, and then a rib-and-sheet part is molded by placing, in a second mold, the rib with either: (i) a preformed sheet, (ii) plies that form a laminate/sheet or (iii) chopped fibers that form a sheet during the molding process. In another embodiment, rib-and-sheet structures are fabricated in a one-step compression-molding process, wherein fiber-bundle-based preforms and (i) a preformed sheet, (ii) plies that form a laminate/sheet, or (iii) chopped fibers are combined in a single mold and molded in a single step.

Abstract: An apparatus and method for manufacturing fiber composite parts from a raw fiber tow to a finished composite part in a single continuous process are provided. The apparatus includes a continuous tow, a preheater/spreader to receive and spread the tow, an injection molding die downstream from the preheater/spreader to form an extrudate filament, a cooler downstream from the injection molding die, a forming die downstream from the cooler to pultrude and shape the cross-section of the extrudate filament, a preformer downstream from the forming die to heat and cut the extrudate filament to create preforms, a compression mold downstream from the preformer to form a finished fiber composite part, and a pick-and-place system to continuously pick each preform from the preformer and place each preform into the compression mold.

Abstract: A preform charge is formed by forming an assemblage of preforms, wherein preforms in the assemblage are bonded to a neighboring preform such that the preform charge effectively becomes a single unit. The preform charge can then be added to a mold to fabricate a part via compression molding.

Abstract: A method of reprocessing a fiber composite part to form a preform is provided including determining a location having a longest stretch of continuous, unidirectional fibers in the part, determining an axis generally closest to and parallel to the fibers at the location, suspending the part from an anchor point within a heated cavity, heating the part to a temperature above a glass transition temperature and below a melting temperature of the resin of the part, and applying at least one force vector to the composite part, the sum of such vectors being parallel to the axis, wherein fibers of the part realign in a direction generally parallel to the sum of the force vectors, and wherein the composite part yields in the direction of the at least one applied force vector to provide a preform.

Abstract: An apparatus for molding a part includes a plunger cavity, a plunger, and a mold cavity, wherein the plunger is oriented out-of-plane with respect to a major surface of the mold cavity, and first and second vents couples to respective first and second portions of the mold cavity. In a method, resin and fiber are forced into the mold cavity from a plunger cavity, and at least some of the fibers and resin are preferentially flowed to certain region in the mold cavity via the use of vents.

Abstract: An apparatus for molding a part includes a plunger cavity, a plunger, and a mold cavity, wherein the plunger is oriented out-of-plane with respect to a major surface of the mold cavity, and first and second vents couples to respective first and second portions of the mold cavity. In a method, resin and fiber are forced into the mold cavity from a plunger cavity, and at least some of the fibers and resin are preferentially flowed to certain region in the mold cavity via the use of vents.

Abstract: A method for forming fiber-reinforced composite parts via compression molding, particularly useful for forming parts that include off-axis, out-of-plane, or small, intricate features. In accordance with the method, non-flowing continuous fiber bundles and flowing continuous fiber bundles are placed in a mold, wherein the flowing continuous fiber bundles are disposed proximal to a minor feature. The non-flowing bundle has a length about equal to the length of a major feature of the mold. The flowing bundle has a length that is somewhat longer than the length of the minor feature. Under heat and pressure, resin softens and fibers from the flowing continuous fiber bundles flow into the minor feature.

Abstract: A structural support beam having a top wall joined to a side wall at an angle substantially different from a right angle. When installed in a facility or machine with the side wall parallel to a vertical reference, no surface on the support beam is parallel to a horizontal reference, thereby providing for rapid and thorough draining of water deposited on any surface of the beam. Some beam embodiments place the top wall at an angle of about twenty degrees above a horizontal reference when the beam is installed. Alternatively, the top wall may be at an angle of about twenty degrees below the horizontal reference. Some beam embodiments have an open side. Alternatively, a bottom wall may be attached to a side wall to form a tubular support beam. A support beam may include a lower beam joined to an upper beam by a connector bar.

Abstract: A structural support beam having a top wall joined to a side wall at an angle substantially different from a right angle. When installed in a facility or machine with the side wall parallel to a vertical reference, no surface on the support beam is parallel to a horizontal reference, thereby providing for rapid and thorough draining of water deposited on any surface of the beam. Some beam embodiments place the top wall at an angle of about twenty degrees above a horizontal reference when the beam is installed. Alternatively, the top wall may be at an angle of about twenty degrees below the horizontal reference. Some beam embodiments have an open side. Alternatively, a bottom wall may be attached to a side wall to form a tubular support beam. A support beam may include a lower beam joined to an upper beam by a connector bar.

Abstract: A drying apparatus for use with many kinds of objects, but is particularly suited for use in drying most kinds of produce and vegetables including leaf vegetables. In one embodiment, the dryer includes a canted drum design which provides a number of benefits and advantages over prior art designs. The canted design allows the use of a spin drying method that breaks up clumps of material in the dryer and assists in the even distribution of material, thereby improving load balance. The canted design provides ergonomic advantages to the operator when loading and unloading the dryer, and, the canted design allows easy access to the drive system for maintenance and repairs.

Abstract: The invention relates to a piezoelectric motor comprising a piezoelectric component that is connected to a resonator and a two-dimensional resonator that interacts with a movable element, the resonator having principal surfaces that are parallel to each other and that are also identical in shape and size. The invention further relates to methods for producing such piezoelectric motors, wherein the resonators are manufactured by cutting a profiled, extruded bar into lengths or by cutting, preferably by punching, from sheet metal having constant thickness. Finally, this invention relates to a method for exciting such a piezoelectric motor, wherein the excitation frequency or frequencies is/are generated by the control electronics as a function of time in response to the respective peak current and/or in response to the respective phase minimum between current and voltage and/or in response to the change in phase.

Abstract: A piezoelectric motor has a piezoelectric element that is connected to a resonator, and a driven element that interacts with the piezoelectric motor. During the service life of the motor and resonator at least one operating state variable changes, and the change in operating variable is used to help avoid failure of the piezoelectric motor.