Abstract: A vacuum bag system (VBS) for forming pre-consolidated composite blanks has a blank enclosure for sealing around a periphery of the blank, while leaving a second side of the blank exposed, an articulated forming caul (AFC) with at least two facets, each facet effectively jointedly coupled to an adjacent facet, and having a respective, independently controlled, heater integrated with, or coupled to the facet. The VBS further has a forming enclosure for sealing around a periphery of a tool. The blank enclosure brings the blank and the facets into uniform thermal contact resistance and mechanical contact; and permits the articulated AFC to distribute thermal and mechanical load across the blank during forming, even as the facets move to align to faces of the mold.

Abstract: A vacuum bag system (VBS) for forming pre-consolidated composite blanks has a blank enclosure for sealing around a periphery of the blank, while leaving a second side of the blank exposed, an articulated forming caul (AFC) with at least two facets, each facet effectively jointedly coupled to an adjacent facet, and having a respective, independently controlled, heater integrated with, or coupled to the facet. The VBS further has a forming enclosure for sealing around a periphery of a tool. The blank enclosure brings the blank and the facets into uniform thermal contact resistance and mechanical contact; and permits the articulated AFC to distribute thermal and mechanical load across the blank during forming, even as the facets move to align to faces of the mold.

Abstract: A method of manufacturing a flexible element configured for pressing against composite material received on a mold surface of a mold during cure, including placing a porous material over the mold surface, forming a sealed enclosure containing the mold surface and the porous material, infusing a curable liquid material such as silicone in liquid form into the enclosure under vacuum and through the porous material, curing the liquid material to form the flexible element, and opening the enclosure and disengaging the flexible element from the mold. In a particular embodiment, the flexible element is a pressure pad.

Abstract: A method of manufacturing a monolithic component having internal wall(s), including separately placing uncured composite material on a mold parts, placing the mold parts on a support plate with a portion of the uncured composite material extending between and in contact with the adjacent mold parts, interconnecting the adjacent mold parts through a connection allowing limited relative movement on the support plate along a direction corresponding to a thickness of the uncured composite material therebetween, biasing the adjacent mold part toward each other along the limited relative movement to provide a compressive force on the uncured composite material extending therebetween, and curing the composite material to obtain the monolithic component with each internal wall being formed between adjacent mold parts. The bias causes the adjacent mold parts to move toward each other as the thickness of uncured material extending therebetween reduces during curing. A tool assembly is also discussed.

Abstract: A method of manufacturing a flexible element configured for pressing against composite material received on a mold surface of a mold during cure, including placing a porous material over the mold surface, forming a sealed enclosure containing the mold surface and the porous material, infusing a curable liquid material such as silicone in liquid form into the enclosure under vacuum and through the porous material, curing the liquid material to form the flexible element, and opening the enclosure and disengaging the flexible element from the mold. In a particular embodiment, the flexible element is a pressure pad.

Abstract: A method of manufacturing a monolithic component having internal wall(s), including separately placing uncured composite material on a mold parts, placing the mold parts on a support plate with a portion of the uncured composite material extending between and in contact with the adjacent mold parts, interconnecting the adjacent mold parts through a connection allowing limited relative movement on the support plate along a direction corresponding to a thickness of the uncured composite material therebetween, biasing the adjacent mold part toward each other along the limited relative movement to provide a compressive force on the uncured composite material extending therebetween, and curing the composite material to obtain the monolithic component with each internal wall being formed between adjacent mold parts. The bias causes the adjacent mold parts to move toward each other as the thickness of uncured material extending therebetween reduces during curing. A tool assembly is also discussed.

Abstract: A sulky shaft connector device includes a swivel ball joint arrangement whereby the sulky shaft is allowed relative damped vertical movement with respect to the harness. A sulky shaft connector member, removably connected to the sulky shaft, forming part of the device also provides for quick and releasable engagement between the sulky shaft and the sulky shaft connector device.

Abstract: Articles containing thermoplastic material are welded together by placing a heating element between an overlapping side edges of the articles to define a weld area between the overlapping side edges with the heating element extending outwardly therebeyond, effecting relative movement between electrodes in contact with the exposed sides of the heating element and the articles while applying current to the electrodes to create a moving localized melt zone, and applying pressure to the melt zone immediately following creation of the zone to fuse the articles to each other and to the heating element.

Abstract: A sulky shaft connector device includes a swivel ball joint arrangement whereby the sulky shaft is allowed relative damped vertical movement with respect to the harness. A sulky shaft connector member, removably connected to the sulky shaft, forming part of the device also provides for quick and releasable engagement between the sulky shaft and the sulky shaft connector device.

Abstract: A racing sulky is provided with wheel mounting forks that are angularly orientated rearwardly away from the shafts to locate the wheel axis rearward of the center of mass of the sulky, the angular orientation lying in the range 1° to 40°. A seat mounted on the sulky rearward of the sulky center of mass and the wheel axis allow the center of mass of a rider to substantially balance the sulky center of mass. A corresponding sulky harness connector is also disclosed.