Abstract: An improved liner for a container in which gases, liquids, or powders are stored. The liner is a multi-layer structure made in a roto molding machine. The liner includes a first outer layer made of metallocene polyethylene, an intermediate gas and liquid impermeable layer, and one or more inner layers made of thermoplastic material compatible with the material stored inside the container. During the molding process, the three layers are made sequentially with the second and third layers being bonded and fused to the adjacent layer to form a uniform composite layer. The outer layer is made of metallocene polyethylene with superior rigidity and relatively low coefficient of thermal expansion making the liner less susceptible to cracking and useful as a layup structure for molding a structure around it. The liner is then used as a layup structure for outer fibers and infused resin.

Abstract: An improved liner for a container in which gases, liquids, or powders are stored. The liner is a multi-layer structure made in a roto molding machine. The liner includes a first outer layer made of metallocene polyethylene, an intermediate gas and liquid impermeable layer, and one or more inner layers made of thermoplastic material compatible with the material stored inside the container. During the molding process, the three layers are made sequentially with the second and third layers being bonded and fused to the adjacent layer to form a uniform composite layer. The outer layer is made of metallocene polyethylene with superior rigidity and relatively low coefficient of thermal expansion making the liner less susceptible to cracking and useful as a layup structure for molding a structure around it. The liner is then used as a layup structure for outer fibers and infused resin.

Abstract: A molded double frame display hanging frame system that is easy to assemble to hang a display object on a vertical surface. The system includes a square or rectangular platform with four, straight perpendicularly aligned outer edges. Attached to the platform's outer edges is the outer frame. Formed on the center region of the platform is a four sided, raised inner frame structure that allows an inner frame to be selectively attached to the front surface of the platform. A plurality of holes are formed at the inside corners of the mounting area adjacent to the inner frame structure which receive pin connectors that hold the display object over the mounting area. A transparent panel may be placed over the display object and held in position by the inner frame. The platform, the outer frame, and the inner frame may be made of molded composite material.

Abstract: A molded double frame display hanging frame system that is easy to assembly to hang a display object on a vertical surface. The system includes a square or rectangular platform with four, straight perpendicularly aligned outer edges. Attached to the platform's outer edges is the outer frame. Formed on the center region of the platform is a four sided, raised inner frame structure that allows an inner frame to be selectively attached to the front surface of the platform. A plurality of holes are formed at the inside corners of the mounting area adjacent to the inner frame structure which receive pin connectors that hold the display object over the mounting area. A transparent panel may be placed over the display object and held in position by the inner frame. The platform, the outer frame, and the inner frame may be made of molded composite material.

Abstract: An improved liner for a container in which gases, liquids, or powders are stored. The liner is a multi-layer structure made in a roto molding machine. The liner includes a first outer layer made of metallocene polyethylene, an intermediate gas and liquid impermeable layer, and one or more inner layers made of thermoplastic material compatible with the material stored inside the container. During the molding process, the three layers are made sequentially with the second and third layers being bonded and fused to the adjacent layer to form a uniform composite layer. The outer layer is made of metallocene polyethylene that has superior rigidity and relatively low coefficient of expansion properties making the liner less susceptible to cracking and useful as a layup structure for molding a structure around it. Once the liner is fabricated, the liner may be a build up structure to manufacturer a container or tank around the liner using either blow molding or roto molding processes.

Abstract: A connecting rod is composed of two or more assembled shells made of a composite, open over the entire length of the connecting rod. The shells incorporate clevis joints for introducing stress at each of their ends. The shells are produced separately then assembled together to form a sealed section. Each shell is made from a material preimpregnated with long fibres. The production of each shell is simplified due to the overall shape of the shell as a simple curve, thus a shell may be produced industrially, for example, by thermoforming a flat composite preform. The two shells are assembled by simultaneous polymerization of the shells, by bonding, by welding, by riveting or any other assembly process or combination of assembly processes that are compatible with one another. The structural composite connecting rod obtained has very good mechanical properties, especially in compression, with a simple and economic production process.

Abstract: A method for manufacturing complex hollow composite parts with at least one internal structure formed in situ by laying laminated layers around a removable mandrel assembled inside the part's inner cavity. The inner mandrel is made up of two jig plate assemblies aligned in a parallel manner and space apart where the internal structure is to manufactured. Each jig plate assembly is made up of at least three jig plates stacked in an edge-to-edge manner Located on opposite sides of each jig plate assembly is an elastic envelope filled with spherical objects. When evacuated, the envelope collapses and relaxes and composite material may then laid up inside the inner cavity and around the envelopes. When exposed to a heat, the envelopes expand and in situ and form internal structures inside surface of the cavity. Each envelope and each jig plate assemblies can be easily dissembled and reused.

Abstract: A method for manufacturing complex hollow composite parts with at least one internal structure formed in situ by laying laminated layers around a removable mandrel assembled inside the part's inner cavity. The inner mandrel is made up of two jig plate assemblies aligned in a parallel manner and space apart where the internal structure is to manufactured. Each jig plate assembly is made up of at least three jig plates stacked in an edge-to-edge manner Located on opposite sides of each jig plate assembly is an elastic envelope filled with spherical objects. When evacuated, the envelope collapses and relaxes and composite material may then laid up inside the inner cavity and around the envelopes. When exposed to a heat, the envelopes expand and in situ and form internal structures inside surface of the cavity. Each envelope and each jig plate assemblies can be easily dissembled and reused.

Abstract: A wrinkle control process for manufacturing a closed cross-sectional, composite laminate structure on a male tool cured under temperature and pressure. The process includes the step of creating a plurality of filled or unfilled depressions at strategic locations in the laminate prior to curing. The depressions are created by depression forming elements that have a predetermined size designed to create a depression in under plies, alone or combined with intensification techniques. The depressions may be left unfilled or be partially or completely filled. Depression forming elements are removed after cure or remain part of the structure.

Abstract: A tubular part with a complex geometrical shape, the tubular part is made of a composite material including, on the one hand, a core part made of a very high-temperature resin obtained by a 3-D direct-creation method using a very high-temperature thermoplastic resin and, on the other hand, a coating of resin-impregnated fibres. The part includes, for example, at least one internal separation of the tube into several conduits that do not communicate with one another. The part is suitable for conveying air flows in opposite or separate directions. One of the conduits can be a dedicated cable raceway.

Abstract: A method for making parts (6) having a complex geometrical shape, the geometrical shape including e.g. various bends, branching, deflectors, sections or thickness, that includes the steps of: forming a core part (1) having a geometry substantially similar to that of the target shape, except for the outer thickness, using a three-dimensional creation method; wrapping at least a portion of the core part with fibres previously or subsequently impregnated with resin until the final dimensions of the target shape are reached; and curing the resin.

Abstract: An improved mold for molding composite structures inside the closed cavity of the mold that uses a projecting tool member, a compression plate and at least two side plates located inside an expansion cavity formed in the mold. The mold includes a base made up of two mold sections that when jointed form a partially enclosed mold cavity. Located over the mold cavity are two side plates each with an inside beveled edge. The side parts are aligned inside the expansion cavity so that the two beveled edges are adjacent a form a large V-shape void. The compression plate includes a V-shaped projection that fits into the V-shaped void. The improvement includes a U-shaped, heat expandable boot located between the inside surfaces of the projecting tool member, the inside surfaces of the two side plates, and the inside surfaces of the mold that evenly distributes the external forces and evenly distributes the forces created by expansion during the curing stage to product structures with uniform side walls.

Abstract: The invention relates to a method for making a thermoplastic composite part by molding. The method includes making several portions of the part according to a molding method, the molding method including placing, in a mold, a composite material containing fibers embedded in a thermoplastic matrix, while arranging the material so that the fibers contained therein are oriented along one or more preferred directions; submitting the mold to particular pressure and temperature conditions, knowing that for each of the different portions the fibers may be of different natures and dimensions, and may be oriented in different directions, while the thermoplastic matrix and that of the material used for making the first portion are identical or compatible; and assembling the different portions obtained, placing them in a mold, and submitting the latter to particular pressure and temperature conditions.

Abstract: A connecting rod is composed of two or more assembled shells made of a composite, open over the entire length of the connecting rod. The shells incorporate clevis joints for introducing stress at each of their ends. The shells are produced separately then assembled together to form a sealed section. Each shell is made from a material preimpregnated with long fibres. The production of each shell is simplified due to the overall shape of the shell as a simple curve, thus a shell may be produced industrially, for example, by thermoforming a flat composite preform. The two shells are assembled by simultaneous polymerization of the shells, by bonding, by welding, by riveting or any other assembly process or combination of assembly processes that are compatible with one another. The structural composite connecting rod obtained has very good mechanical properties, especially in compression, with a simple and economic production process.

Abstract: The invention relates to a method for making a thermoplastic composite part by molding. The method includes making several portions of the part according to a molding method, the molding method including placing, in a mold, a composite material containing fibers embedded in a thermoplastic matrix, while arranging the material so that the fibers contained therein are oriented along one or more preferred directions; submitting the mold to particular pressure and temperature conditions, knowing that for each of the different portions the fibers may be of different natures and dimensions, and may be oriented in different directions, while the thermoplastic matrix and that of the material used for making the first portion are identical or compatible; and assembling the different portions obtained, placing them in a mold, and submitting the latter to particular pressure and temperature conditions.

Abstract: A wrinkle control process for manufacturing a closed cross-sectional, composite laminate structure on a male tool cured under temperature and pressure. The process includes the step of creating a plurality of filled or unfilled depressions at strategic locations in the laminate prior to curing. The depressions are created by depression forming elements that have a predetermined size designed to create a depression in under plies, alone or combined with intensification techniques. The depressions may be left unfilled or be partially or completely filled. Depression forming elements are removed after cure or remain part of the structure.

Abstract: A method for producing a composite material part having a so-called non-strippable shape includes producing mold components, or cores, which are to be extracted from the part after the composite material has been cured. In a first step a core is produced from an elastomeric bladder the granular solid material and the bladder is depressurized. In a second step, after setting the core and the composite material the volume of the core is modified in a controlled manner for example by selecting the solid granular material based on its thermal expansion properties or by acting on the pressure in the bladder.