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 reinforced composite pallet assembly of the sandwich-type having a cellular core which is locally crushed is provided. The assembly includes a pair of substantially flat decks having front, back and side edges. Each of the decks includes a load-bearing skin made of a reinforced thermoplastics material, a grid of reinforcing slats, a cellular core made of a thermoplastics material, and a tine-engaging skin made of a reinforced thermoplastics material. The grid of reinforcing slats is positioned at predetermined places against the tine-engaging skins. The distance between the skins of each deck is reduced during molding of the deck which molding locally crushes the core at the predetermined places. A plurality of supports support the decks at the predetermined places against the reinforcing slats so that tines can lift and support the pallet assembly at the tine-engaging skin. The resulting assembly is ultra light weight, meeting all forecasted government weight restrictions.

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 positioning 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 method of manufacturing articles utilizing a composite material having a high density of small particles such as microspheres in a matrix material is disclosed. In accordance with one aspect of the present invention, at least first and second layers of flanking material are disposed in a generally non-parallel relationship with respect to each other and then are pulled through a die. While the flanking material layers are being pulled through the die, a composite material is injected into a space defined between the at least first and second layers of flanking material. The composite material and the at least first and second layers of flanking material are heated as they pass through the die to cure the composite material and bond the at least two flanking material layers to the composite material, thereby forming a cured article.

Abstract: A reinforced composite pallet assembly of the sandwich-type having a cellular core which is locally crushed is provided. The assembly includes a pair of substantially flat decks having front, back and side edges. Each of the decks includes a load-bearing skin made of a reinforced thermoplastics material, a grid of reinforcing slats, a cellular core made of a thermoplastics material, and a tine-engaging skin made of a reinforced thermoplastics material. The grid of reinforcing slats is positioned at predetermined places against the tine-engaging skins. The distance between the skins of each deck is reduced during molding of the deck which molding locally crushes the core at the predetermined places. A plurality of supports support the decks at the predetermined places against the reinforcing slats so that tines can lift and support the pallet assembly at the tine-engaging skin. The resulting assembly is ultra light weight, meeting all forecasted government weight restrictions.

Abstract: A method of manufacturing articles utilizing a composite material having a high density of small particles such as microspheres in a matrix material is disclosed. In accordance with one aspect of the present invention, at least first and second layers of flanking material are disposed in a generally non-parallel relationship with respect to each other and then are pulled through a die. While the flanking material layers are being pulled through the die, a composite material is injected into a space defined between the at least first and second layers of flanking material. The composite material and the at least first and second layers of flanking material are heated as they pass through the die to cure the composite material and bond the at least two flanking material layers to the composite material, thereby forming a cured article.

Abstract: A method of manufacturing articles utilizing a composite material having a high density of small particles such as microspheres in a matrix material is disclosed. One aspect of the present invention is that at least first and second layers of flanking material that are disposed in a generally non-parallel relationship with respect to each other are pulled through a die while a composite material is injected into a space defined between the at least first and second layers of flanking material. The composite material and the at least first and second layers of flanking material are heated as they pass through the die to cure the composite material and bond the at least two flanking material layers to the composite material, thereby forming a cured article.

Abstract: A method of manufacturing articles utilizing a composite material having a high density of small particles such as microspheres in a matrix material is disclosed. In accordance with one aspect of the present invention, at least first and second layers of flanking material are disposed in a generally non-parallel relationship with respect to each other and then are pulled through a die. While the flanking material layers are being pulled through the die, a composite material is injected into a space defined between the at least first and second layers of flanking material. The composite material and the at least first and second layers of flanking material are heated as they pass through the die to cure the composite material and bond the at least two flanking material layers to the composite material, thereby forming a cured article.

Abstract: A method of manufacturing articles utilizing a composite material having a high density of small particles such as microspheres in a matrix material is disclosed. In accordance with one aspect of the present invention, at least first and second layers of flanking material are disposed in a generally non-parallel relationship with respect to each other and then are pulled through a die. While the flanking material layers are being pulled through the die, a composite material is injected into a space defined between the at least first and second layers of flanking material. The composite material and the at least first and second layers of flanking material are heated as they pass through the die to cure the composite material and bond the at least two flanking material layers to the composite material, thereby forming a cured article.

Abstract: A method of manufacturing articles utilizing a composite material having a high density of small particles such as microspheres in a matrix material is disclosed. In accordance with one aspect of the present invention, at least first and second layers of flanking material are disposed in a generally non-parallel relationship with respect to each other and then are pulled through a die. While the flanking material layers are being pulled through the die, a composite material is injected into a space defined between the at least first and second layers of flanking material. The composite material and the at least first and second layers of flanking material are heated as they pass through the die to cure the composite material and bond the at least two flanking material layers to the composite material, thereby forming a cured article.

Abstract: A method of manufacturing articles utilizing a composite material having a high density of small particles such as microspheres in a matrix material is disclosed. In accordance with one aspect of the present invention, at least first and second layers of flanking material are disposed in a generally non-parallel relationship with respect to each other and then are pulled through a die. While the flanking material layers are being pulled through the die, a composite material is injected into a space defined between the at least first and second layers of flanking material. The composite material and the at least first and second layers of flanking material are heated as they pass through the die to cure the composite material and bond the at least two flanking material layers to the composite material, thereby forming a cured article.

Abstract: A method and system for producing an article using a thermoplastic sandwich material such as, for example, a 3-D deep-drawn article is disclosed. In accordance with an aspect of the present invention, two reinforced thermoplastic skins surround a generally planar honeycomb structure. During the manufacturing process, the skins and the honeycomb structure are bonded together by means of a thermocoupling process.