Abstract: In the expansion held prepeg composite (100) disclosed herein, using a flexible and expandable tubular core (101), one or more set of fibers are linearly placed over the circumference of the tubular core (101); and one or more set of fibers with predetermined tensions are wound over the linear fibers to create an expansion held prepeg composite (100). At least one of the set of fibers is precoated with resin. The tension of wrapping of each subsequent set of fibers is higher than its precedent wound layer. A bladder tube is inserted into the tubular core (101) of the expansion held prepeg composite 100. The expansion held prepeg composite (100) is a held in the desired three dimensional shape. Compressed air is introduced into the bladder tube and cured. At least one of the sets of fiber must be impregnated with resin.

Abstract: An apparatus and method for manufacturing a composite is provided. A bottom release layer is disposed within a cavity of a volumetrically restraining body structure for supporting a cast material. An air bag is disposed between the bottom release layer and one or more surfaces of the volumetrically restraining body structure within the cavity. An air compressor connected to the air bag pressurizes the air bag. The pressurized air bag compresses the cast material against the bottom release layer. The resin inlets disposed on the cast material infuse resin into the cast material. A vacuum outlet insertably connected in the cavity of the volumetrically restraining body structure, in communication with the cast material, draws a vacuum through the cast material and draws the resin into the cast material. The compression of the cast material reduces excessive resin rich areas in the composite created from the resin infused cast material.

Abstract: An apparatus and a method for a continuous manufacture of an expanded composite honeycomb block are provided. Resin impregnated fibers are deposited on a conformable thin membrane that moves over a heated bed with a corrugated surface. A vacuum is applied between the conformable thin membrane and the heated bed to conform the resin impregnated fibers to the shape of the corrugated surface of the heated bed. A stacker is lowered to contact the corrugated resin impregnated fibers on top nodes of the corrugated surface of the heated bed. The corrugated resin impregnated fibers are heat cured. The stacker is raised to lift the heat cured corrugated resin impregnated fibers after the corrugated resin impregnated fibers release from the conformable thin membrane. The above steps are repeated until the stacker stacks layers of the corrugated resin impregnated fibers to a desired thickness to manufacture the expanded composite honeycomb block.

Abstract: A radiolucent patient table top including a first face sheet, a second face sheet, and a honeycomb core is provided. The first face sheet includes carbon fibers in a first radiolucent plastic matrix. The second face sheet includes carbon fibers in a second radiolucent plastic matrix. The honeycomb core is disposed between the first face sheet and the second face sheet, where the first face sheet and the second face sheet sandwich the honeycomb core. The honeycomb core includes carbon fibers embedded in a third radiolucent plastic matrix.

Abstract: A radiolucent patient table top including a first face sheet, a second face sheet, and a honeycomb core is provided. The first face sheet includes carbon fibers in a first radiolucent plastic matrix. The second face sheet includes carbon fibers in a second radiolucent plastic matrix. The honeycomb core is disposed between the first face sheet and the second face sheet, where the first face sheet and the second face sheet sandwich the honeycomb core. The honeycomb core includes carbon fibers embedded in a third radiolucent plastic matrix.

Abstract: A high color quality, fire resistant, pinstripe decorative fiberglass laminate is provided. The pinstripe decorative fiberglass laminate includes colored unidirectional glass fiber rovings in a fire resistant resin matrix. Pigmented unidirectional glass fiber rovings provide a pinstriped effect with substantial color richness and aesthetic quality. For light colored pinstripes, colored unidirectional glass fiber rovings are impregnated with a melamine resin and cured to form the fire resistant, pinstripe decorative fiberglass laminate. For dark colored pin stripes, colored unidirectional glass fiber rovings are impregnated with a phenolic resin and cured to form the fire resistant, pinstripe decorative fiberglass laminate.

Abstract: A metal fiber composite cellular structure includes cell walls composed of metal foils. At least two of the cell walls of each cell of the metal fiber composite cellular structure further includes a continuous fiber roving coated in an adhesive resin adhered to the metal foil, which creates continuous fiber adhesive node bond lines. The continuous fiber adhesive node bond lines improve compressive properties and shear properties of the metal fiber composite cellular structure without a weight penalty when used to manufacture sandwich structures.

Abstract: A method for decorating a composite placed in a mold in a resin transfer molding process includes selectively depositing unbonded pigments on one or more areas of a preform of the composite, and injecting a resin into the mold via one or more resin input ports operably connected to the mold. The injected resin carries the selectively deposited unbonded pigments on a path on one or more areas of the preform of the composite along a direction of flow of the injected resin, thereby creating ornamental pigment flow patterns in the composite for decorating the composite. The method also creates bands of ornamental pigment flow patterns by depositing the unbonded pigments on a transfer medium positioned on the composite, positioning the transfer medium in proximity to the resin input ports, and selectively injecting the resin onto the transfer medium deposited with the unbonded pigments, via the resin input ports.

Abstract: A composite having a core containing a cellular structure, reinforcing fibers, an upper face sheet, and a lower face sheet is provided. The cellular structure is a honeycomb structure containing strips of carrier material arranged in an x direction in an x-y plane, adhered together, and expanded in the x direction after adhesion. The reinforcing fibers are externally bonded onto the outer walls of each of the cells of the cellular structure in a z direction. The upper face sheet and the lower face sheet are configured to be bonded to the upper portion and the lower portion of the reinforcing fibers that extend outwardly from the upper edges and the lower edges of the cells of the cellular structure respectively, thereby establishing a three dimensional continuity of the reinforcing fibers between a surface of contact between the core, the upper face sheet, and the lower face sheet.

Abstract: A method of manufacturing a body structure for a door or other furniture is provided. A skeletal framework is placed on an uncured artificial stone mix deposited on a release sheet placed on a surface. Liquid structural foam is introduced within the skeletal framework. The skeletal framework is wrapped with the release sheet comprising the uncured artificial stone mix such that the skeletal framework is completely covered with the uncured artificial stone mix. The wrapped skeletal framework is placed in a chamber of a defined volume. The uncured artificial stone mix is compressed by the expanding liquid structural foam and conforms to the internal shape of the chamber. The foaming action generates heat that accelerates curing of the uncured artificial stone mix to create an outer cured artificial stone skin of the body structure. After removal from the chamber, the release sheet is separated and the body structure is polished.

Abstract: A method for decorating an artificial stone laminate, for example, a quartz resin composite is provided. In the manufacturing process, a substantially thin layer of transparent or translucent particulates is deposited on a release surface. Color pigments or any coloring material that imparts color and/or contrast are selectively deposited in areas on the transparent or translucent particulates to create patterns and designs. A layer of reinforcing fibers, for example, glass fibers, is placed on the layer of transparent or translucent particulates. A binder, deposited on the layer of reinforcing fibers, fills gaps between the transparent or translucent particulates and binds the reinforcing fibers to the transparent or translucent particulates.

Abstract: An apparatus and method for manufacturing a composite is provided. A bottom release layer is disposed within a cavity of a volumetrically restraining body structure for supporting a cast material. An air bag is disposed between the bottom release layer and one or more surfaces of the volumetrically restraining body structure within the cavity. An air compressor connected to the air bag pressurizes the air bag. The pressurized air bag compresses the cast material against the bottom release layer. The resin inlets disposed on the cast material infuse resin into the cast material. A vacuum outlet insertably connected in the cavity of the volumetrically restraining body structure, in communication with the cast material, draws a vacuum through the cast material and draws the resin into the cast material. The compression of the cast material reduces excessive resin rich areas in the composite created from the resin infused cast material.

Abstract: A lighting apparatus for providing illumination within a furniture module is provided. The lighting apparatus comprises a means of capturing kinetic energy of a moving part of the furniture module, a means for converting the kinetic energy into electric energy, and a means of converting the electric energy into light energy for lighting up the space within the furniture module. The lighting apparatus is attached to the furniture module. The means of converting kinetic energy into electric energy is, for example, a mechanical gear based assembly or a piezoelectric crystal based assembly. The light source is activated using a rechargeable battery or by using a continuously generated electric current in the short duration of the operation of the furniture module. The lighting apparatus is either directly attached to the furniture module or is an integral part of a furniture hinge.

Abstract: An artificial stone laminate including a layer of particulates, a layer of reinforcing fibers backing the layer of particulates, a substrate attachment layer backing the layer of reinforcing fibers, and a binder that binds the particulates, the reinforcing fibers, and the substrate attachment layer is provided. An exposed surface of the layer of particulates is polished flat. The reinforcing fibers include, for example, glass fibers. The substrate attachment layer is, for example, a cellulosic layer, a layer of cenospheres, a layer of fleece, or a layer having a hook side or a loop side of a hook and loop fastener. The binder is, for example, a polyester resin with a filler or an acrylic resin. The particulates include, for example, one or more of quartz particulates, metal pieces, transparent particulates coated with metal and colored glass, or any combination thereof.

Abstract: A surface material is provided for furniture and building structures. The surface material comprises a layer of artificial stone and a layer of fiber reinforced resin. The surface material may further comprise a separator material, for example, a metal strip, a fiber strip, etc. that defines partially or wholly a boundary edge of the layer of artificial stone. The layer of fiber reinforced resin partially or fully encompasses the artificial stone and/or the separator material on all sides and surfaces except exposed decorative surfaces. The surface material may further comprise a decorative material comprising, for example, ornamental glass, semiprecious stones, metal art, colored quartz, glass, stone jewelry, etc. embedded within the layer of artificial stone. The surface material is used to cover a central core for forming the furniture and the building structures.

Abstract: A method of manufacturing a decorative surface of a furniture body or building structure comprises: manufacturing a layer of an art release sheet, depositing an uncured artificial stone mix on the art release sheet, compacting, and wrapping the art release sheet around a central core. The uncured artificial stone mix is allowed to partially or fully cure, wherein the art units in the art release sheet are embedded in the artificial stone mix. The decorative surface may be manufactured by loading an art deposit frame with art particles of a predetermined quantity and size, placing and vibrating the loaded art deposit frame on a base layer to create an art unit, and depositing an uncured artificial stone mix on the base layer comprising the art unit. Pressure is applied on the uncured artificial stone mix to compact and allow the artificial stone mix to partially or fully cure.

Abstract: A short fiber reinforced artificial stone laminate comprising a top layer of particulates of substantially a single size between 0.5 mm and 3 mm, short fibers deposited in grooves between the particulates, a rear layer of long reinforcing fibers backing the particulates and the short fibers, and a binder is provided. A method for manufacturing the short fiber reinforced artificial stone laminate is also provided. Particulates, for example, quartz particulates, are deposited on a release surface. Short fibers, for example, short glass fibers, are deposited in grooves between the particulates. The particulates and the short fibers are vibrated, whereby the short fibers align and position themselves in the grooves. Long reinforcing fibers are then deposited on the particulates. A binder is deposited for binding the particulates, the short fibers, and the long reinforcing fibers. After the binder cures, the surface of the particulates is polished.

Abstract: A method for decorating a composite placed in a mold in a resin transfer molding process includes selectively depositing unbonded pigments on one or more areas of a preform of the composite, and injecting a resin into the mold via one or more resin input ports operably connected to the mold. The injected resin carries the selectively deposited unbonded pigments on a path on one or more areas of the preform of the composite along a direction of flow of the injected resin, thereby creating ornamental pigment flow patterns in the composite for decorating the composite. The method also creates bands of ornamental pigment flow patterns by depositing the unbonded pigments on a transfer medium positioned on the composite, positioning the transfer medium in proximity to the resin input ports, and selectively injecting the resin onto the transfer medium deposited with the unbonded pigments, via the resin input ports.

Abstract: An artificial stone laminate comprising a top single layer of particulates of substantially a single size, a rear layer of reinforcing fibers, and a binder is provided. The single size of the particulates is between 0.5 mm and 3 mm. Each of the particulates has an exposed top flat surface section area that is substantially the largest sectional area that can be exposed in the particulates. A single layer of particulates of uniform size is spread on a release surface. The single layer of particulates is vibrated whereby the particulates are packed closely, touch one another adjacently in a horizontal plane, and achieve high surface coverage. The layer of reinforcing fibers is placed on the single layer of particulates. A binder is deposited for filling the gaps between the particulates and bonding the reinforcing fibers to the particulates. After the binder cures, the surface of the single layer of particulates is polished.

Abstract: A method of inserting metal wire elements in an artificial stone is provided. One or more metal wire elements in multiple arrangements are placed on a surface. An uncured artificial stone mix is deposited on the metal wire elements and on the surface. The uncured artificial stone mix is allowed to cure at room temperature or at an elevated temperature and transformed into an artificial stone inserted with the metal wire elements. The artificial stone comprising the inserted metal wire elements is polished thereby generating a flat metal surface that visually implies metal inlay work. The metal wire elements may also be laid or adhered to a release layer deposited on the surface prior to depositing the uncured artificial stone mix. The metal wire used to create the metal wire elements comprises holes for secure anchoring in the artificial stone. The metal wire cross-section may be polygonal or circular.