Abstract: An apparatus and method for making a mold or mold face includes a container having at least one opening. The apparatus also includes a flexible membrane that is retained to the container that extends across the opening of the container. The apparatus for making a mold further includes support media that is disposed within the container along with a vacuum valve that is connected to the container.

Abstract: A layered material for use in transparent, flame resistant components couples a thin, fire resistant outer polymeric film to a thicker, transparent inner polymeric material. The resultant transparent layered material meets FAA flammability requirements for OSU heat release, has excellent solvent resistance and cleanability, is scratch resistant, and is transparent enough for use in interior applications in the aerospace industry. The layered material is formed via a co-extrusion or co-lamination process.

Abstract: There is provided an ultrasonic welding apparatus that includes a magnetic source and a ferromagnetic device to apply pressure to at least one component being joined during the ultrasonic welding process. The magnetic source is positioned proximate the ultrasonic transducer, and when the component to be ultrasonically welded is adjacent the ultrasonic transducer, the ferromagnetic device is positioned opposite the component from the magnetic source and the ultrasonic transducer to apply pressure. A magnetic source comprising an electromagnet provides an adjustable pressure to the component. The ferromagnetic device defines a generally spherical surface so that it advantageously remains in position relative to the magnetic source if the component is moved relative to the ferromagnetic device. In addition, the ferromagnetic device may comprise a magnet to increase the magnetic force between the magnetic source and ferromagnetic device, which increases the pressure applied to the component.

Abstract: A translucent composite material that can be used in various airplane interior applications that allows sufficient light transmissivity while preferably meeting Federal Aviation Administration (FAA) flammability requirements for overhead materials in the cabin of a commercial aircraft. The material also meets FAA standards regarding vertical burn, smoke emissions tests, and toxic fume emissions tests. The composite material is formed by laminating long glass fibers and (PPSU) into a composite sheet under controlled heat and pressure. The composite sheet is then cut, bent or thermoformed to form the desired part. The parts formed are available for a wide variety of uses within the passenger cabin of a commercial aircraft. The long glass fibers may be unidirectional or weaved into a glass cloth like material. While preferably formed for airplane interior applications, these components may also be used in other aerospace or non-aerospace applications.

Abstract: An apparatus and method for making a mold or mold face includes a container having at least one opening. The apparatus also includes a flexible membrane that is retained to the container that extends across the opening of the container. The apparatus for making a mold further includes support media that is disposed within the container along with a vacuum valve that is connected to the container.

Abstract: Reaction injection molded (RIM) members and a method for forming such members are provided. The members can be formed in a mold cavity defining a contour that corresponds to the desired contour of the members. A foam material, such as a combination of polyol and isocyanate is injected into the cavity with a blowing agent so that the foam material expands to form the low density member. The average density of the member can be less than about 6 pounds per cubic foot.

Abstract: A mobile platform interior panel is provided that includes a body formed by a low pressure injection process and at least one of a duct and a layer of insulation integrated with the body. The low pressure injection process allows the duct and insulation to be integrated with the body simultaneously with the forming of the panel. More specifically, the duct is integrated with the panel by forming at least one internal cavity within the panel as the panel is formed. Additionally, the insulation is integrated with the panel by forming the panel using a low pressure injection material having desired insulative properties.