Abstract: A skateboard deck and a method of manufacturing a skateboard deck is provided without requiring the use of industrial-grade machinery. Precut layers of veneer or other suitable material are coated with adhesive and stacked on a one-sided, negative-contoured mold and placed in a flexible-walled, airtight container from which the air is evacuated, so as to place pressure on the container and force the layers to conform to the contours of the mold. The air evacuation may be accomplished by means of a hand operated, non-electric vacuum pump.

Abstract: A method of manufacturing a hollow section grid-stiffened panel comprises providing a tool (10) having a surface (12). The stiffened skin composite panel is preassembled comprising laminating a composite outer skin (14) on the surface, placing a separator outer layer (16) on the composite outer skin (14), and laminating a composite stiffener (20) on the mandrel (18), the mandrel being positioned on the separator layer (16), wherein the separator layer (16) separates the stiffener (20) and the mandrel (18) from the outer composite skin (14). The preassembled outer skin composite panel is cured on the tool. The separator layer (16) and mandrel (18) are removed from the preassembled stiffened skin composite panel. The stiffened skin composite panel is reassembled, comprising applying an adhesive between the composite outer skin (14) and the composite stiffener (20). The reassembled stiffener skin composite panel is cured on the tool to bond the stiffener skin to the outer skin.

Abstract: A method of producing a ceramic stack is provided, including the steps of providing at least a first ceramic green sheet to be formed into a long ceramic plate and having a principal surface, providing at least a second ceramic green sheet to be formed into a short ceramic plate and having a length that is less than a length of the principal surface of the first ceramic green sheet, and laminating the second ceramic green sheet to the principal surface of the first ceramic green sheet to form a ceramic green sheet laminate having a lamination border defined between at least a side surface of the second ceramic green sheet and the principal surface of the first ceramic green sheet. The method also includes the steps of forming a member having a curved surface at the lamination border by applying a paste to the lamination border such that the curved surface includes at least one inflection point when viewed in cross-section, and sintering the laminate into an integral unit to form the ceramic stack.

Abstract: A trim component includes a foam backing layer and a foam pad insert laminated between a cover material and a substrate. The foam pad insert provides an area of enhanced cushioning, and has smoothly tapered edges to ensure a smooth surface contour without a visible edge transition on the cover material. The foam pad insert has a lower melting temperature than the foam backing layer, both of which are thermoplastics. A foam pad insert is positioned and fixed on the back surface of the foam backing layer. A substrate material is heated and then laminated and molded with the foam and the cover material. The heat from the substrate partially softens and melts the foam backing layer and the foam pad insert. The partially melted foam pad insert is viscously deformed to form the tapered edges, as dictated by the smoothly varying mold gap spacing of the forming tools.

Abstract: A dual-laminate honeycomb panel permits the use of two or more different materials to form a single panel. In this manner, a retractable covering for an architectural opening may be formed that has a different appearance depending upon which side of the panel is being viewed. The resultant panel is formed by attaching a plurality of elongated precursor tubular cells, wherein each precursor tubular cell itself comprises two strips of material attached to one another.

Abstract: A continuous strip of framing material suitable for use in making filter products that can be provided of indefinite length and which is storable as a flat product capable of being wound into roll form. Moreover, the continuous strip of framing material includes features to create a three-dimensional frame structure for wrapping about filtration media in a manner to provide a strong and effective filter product assembly.

Abstract: A laminated material relatively large in thickness and having a curved surface of small radius, wherein a laminated material (170) as a raw material is provided in which surface plates (181, 182) are fixed to both surfaces of a core material (183) and the surface plate (181) on the internal side of an arc is not fixed to the core material (183) and, with one end side of the laminated material (170) fixed to frames (30, 40), the other end of the surface plate (181) is moved in the direction apart from the core material (183) so as to bend it in arc-shape, the other end being not fixed to the core material (183).

Abstract: Gypsum board having inorganic fiber, preferably glass fiber, preferably glass fiber, includes providing face sheets which have been completely impregnated with a gypsum slurry so as to penetrate through said random interstices between the inorganic fibers and to thereby cover the board surfaces with gypsum slurry. The gypsum board product is formed by passing the wet gypsum board through a board forming station having double forming plates, an upper forming plate having at least a portion thereof being set at a predetermined angle relative to a lower forming plate and having a separation between the forming plates defining a predetermined dimension substantially equal to the desired thickness of the manufactured gypsum board product. The method provides a multilayer gypsum board having a polymeric compound added to unset gypsum so as to provide a gypsum board ready for finishing.

Abstract: A process for making a composite product in which reinforcement fibers are subjected to a composition based on a thermohardening resin and a photoinitiator appropriate to the irradiation by which the composition is to be treated. The resulting pre-impregnated material is introduced into a prepolymerization device, in which the pre-impregnated material is prepolymerized by appropriate irradiation. Lengths of the precomposite are applied to a support, the shape of which is dictated by the shape of one face of the composite part which is to be made, and are stacked one on another in a suitable number and placed snugly against the shape of the support, and the stack is subjected to final molding at a suitable pressure and temperature in order to polymerize the resin and to join the different lengths of precomposite.

Abstract: A presently-preferred process for bending a workpiece includes placing a first portion of the workpiece on a substantially flat surface so that a second portion of the workpiece overhangs an edge of the substantially flat surface, and securing the first portion of the workpiece on the substantially flat surface by clamping the workpiece between the substantially flat surface and a substantially v-shaped end portion of a male die. The presently-preferred process also includes causing the second portion of the workpiece to pivot around a tip of the substantially v-shaped end portion by rotating a bending die around the tip while the bending die contacts the second portion of the workpiece.

Abstract: The female component for engaging a complementary hook component in a refastenable fastening device is capable of engaging a hook component that has flexible, resilient individual hook elements. The female component comprises at least two, and preferably three zones or layers. These include a first zone for admitting and engaging at least some of the hooks of the complementary hook component (the “entanglement” zone), a second zone for providing space for the hooks to occupy after they have been admitted by the entanglement zone (referred to as the spacing zone), and a backing adjacent to the spacing zone. The present invention also provides a fastening device having a hook fastening component and a female component that comprises the multi-layer female component of the present invention. The present invention also relates to disposable articles and more particularly to a disposable diaper having such an improved fastening device.

Abstract: The present invention relates to a gelatinous composite article. The article has a first and a second heat formable and heat reversible gelatinous elastomer material, a first permeable layer, and a control gap. Each of the gelatinous materials is a three-dimensional shape having an upper side, a base side and at least one connecting side. The first connecting side and the second connecting side are adjacent to each other so the first and second materials are essentially side-by-side within the same horizontal plane. The first permeable layer has a top side and a bottom side. The top side attaches to the first and second connecting side. The control gap is interspaced between the bottom side of the first permeable layer. This gap degrades the rigidity between each connecting side and provides an equivalent structural property throughout the article.

Abstract: A method of forming a headliner includes overlaying a cover material onto a multi-layer substrate and at least partially separating the cover material from the substrate during the overlaying. The cover material is clamped separately from the substrate. The overlayed cover material and substrate are then transported into a mold. The substrate is unclamped while the cover material remains clamped, and the cover material and substrate are molded together to form the headliner.

Abstract: Apparatus and methods for manufacturing a folder which has front and back panels with a divider therebetween. The divider front and back panels and divider are taped together along a spine of the folder such that the panels and divider can be turned like the pages of a book. There may be one, two, or three or possibly even more dividers with all of the dividers being secured in place at the spine of the folder. The tape(s) may be pleated so that the panel-to-divider and/or divider-to-divider compartments can expand. This pleating technique can also be employed to give expansibility to the single compartment of a file folder which does not have internal dividers.

Abstract: A thin abrasion resistant decorative thermosetting laminate of positioning quality is glued to a longitudinal carrier. The carrier preferably consists of a fibre board or a particle board with a rectangular cross section and at least two opposite rounded-off edges. One or more floor strips with the same or different cross section is machined from the laminate clad carrier.

Abstract: Seal devices of this invention are prepared by the process of depositing a polymer material onto a metallic substrate to form a composite construction, and shape forming the composite construction into the shape of a seal device. The so-formed seal device comprises a casing member that is formed from the metallic substrate, and a sealing element disposed along a surface of the casing member that is formed from the polymer material for placement against a sealing surface. Seal devices of this invention can be shaped formed into a variety of different types of seals, e.g., lips seals, L-shaped seals, and U-cup seals, which may or may not be energized. Seal devices prepared according to this invention using such preformed composite construction enable seal formation by a single step of shape forming, without having to both make and form individual seal members, and subsequently combine or join the separately formed seal members together.

Abstract: A method and apparatus for manufacturing a flexible curtain as disclosed and claimed. Edges of a polymeric material are folded back on themselves. A portion of the edges are secured and a portion is left unsecured or free. The flexible curtain is used in a windlocking apparatus to prevent the unwanted intrusion of wind, water and debris into a building opening. The free, or unsecured flap of the folded edge absorbs shock associated with storm disturbances. Edge rollers are used to laminate the edges of the curtains selectively such that only a portion of the edge is secured leaving the flap unsecured. Stitching, ultrasonic welding and gluing are alternative ways and/or additional ways of providing for the securement of a portion of the edge to itself. Perforations are made in the secured portion of the folded edge.

Abstract: Plastic panels which are useful as automotive interior trim panels, interior door panels and the like decorative and structural panels, are made by a method which integrates insert sections in the surfaces of the panels and eliminates insert edge trim molding strips. The method includes bonding, via an adhesive film, at least the edge portions of the inserts upon a thin plastic sheet, pre-sized blank, then removing the plastic sheet portions and adhesive film that overlap the insert within the bonded portions; next, positioning the blank in a mold against a mold face and molding in situ and simultaneously bonding a plastic substrate against the blank and the exposed surface of the insert. A substantially continuous, channel forming means, such as a narrow rib or a groove, on the mold face, is overlapped by the bonded insert edge portions and sheet portion, which are folded by said means to form a narrow, relatively deep channel. The insert edges are part of and, consequently, are concealed within the channel.

Abstract: A method is designed to apply a rigid and self-adhesive printed matter to a curved surface of the object. The method includes a first step in which the printed matter is provided with a coating of epoxy resin before the printed matter is baked. After the baking process, the printed matter is contoured to fit the curved surface of the object and is then cooled to take form. The printed matter is attached to the curved surface of the object by the self-adhesive side thereof.

Abstract: Epoxy-modified, two-part acrylic structural adhesives represented by an A-side in a preferred embodiment containing a monomer selected from group (a) and (b), wherein (a) is 4-(C3-C10 alkyl) cyclohexylmethacrylate, 2,5-(C1-C6 alkyl) disubstituted cyclohexylmethacrylate, 3,5-(C1-C6 alkyl) disubstituted cyclohexylmethacrylate.

Abstract: A method for fabricating devices in a pre-assembled state comprising forming plural laminae, registering the laminae, and bonding the laminae one to another is described. The plural laminae contain the substructures and structures of the device. The substructures are coupled to structures and other substructures by fixture bridges in the pre-assembled state. The substructures of the device are dissociated by eliminating the fixture bridges. The plural laminae are registered and bonded to form the device either before or after the fixture bridges are eliminated. The fixture bridges can be eliminated in a variety of ways, including vaporization by electrical current, chemical dissolution, or thermochemical dissociation. One method to selectively bond the laminae together is by microprojection welding. Microprojection welding comprises forming laminae with projections that extend from at least one planar surface of the lamina.

Abstract: The present invention is directed to a method for manufacturing a curved hose. The method is comprised of the steps of (a) forming a hose assembly, the hose assembly comprising: (i) an innermost layer of a halogenated polyolefin rubber; (ii) a polyester reinforcement overlaying the innermost layer, the reinforcement having disposed on its surface an RFL adhesive comprising a chlorosulfonated polyethylene rubber; and (iii) an elastomeric cover overlaying the braided reinforcement; (b) cutting the hose assembly into hose lengths; (c) shaping the hose lengths into predetermined curved hose shapes; and (d) curing the curved hose shapes.

Abstract: A method of manufacturing a composite frame for a side gusset of a bag. The composite frame has a peripheral raised region and a depressed central region. The composite frame is made up of a moldable substrate, e.g. ethyl vinyl acetate foam, an outer layer of wear-resistant material, e.g., high-denier nylon, or poly/nylon combination, and, preferably, an inner adherent layer, e.g., the loop half of a hook-and-loop fabric. During the manufacturing process, a flat sheet of substrate is covered on one side by the wear-resistant material and, preferably, on the other side by the adherent layer. Incisions are cut through a central region of the substrate-adhered materials composite. The composite is then molded to provide the peripheral raised region and the depressed central region, with the raised surface being covered by the wear-resistant material.

Abstract: Methods (and products produced by the methods) are disclosed for sealing the cut end of a concrete reinforcing bar or other long product that comprises a core of mild steel or other corrosion susceptible metal and a cladding of stainless steel or other corrosion resistant metal bonded to an axially extending outer face of the core. The methods include the steps of providing a cap of corrosion resistant material, and shaped for mounting on the cut end of the long product with the exposed portion of the core enclosed by the cap. The cap has a skirt that overlies the cladding adjacent the cut end. A seal is formed in various ways between the skirt and the cladding. The seal may be formed by filling the space between the cut end and the cap with resinous sealant inserted in the cap before it is mounted over the cut end.

Abstract: Apparatus and methods for manufacturing a folder which has front and back panels with a divider therebetween. The divider front and back panels and divider are taped together along a spine of the folder such that the panels and divider can be turned like the pages of a book. There may be one, two, or three or possibly even more dividers with all of the dividers being secured in place at the spine of the folder. The tape(s) may be pleated so that the panel-to-divider and/or divider-to-divider compartments can expand. This pleating technique can also be employed to give expansibility to the single compartment of a file folder which does have internal dividers.

Abstract: A method for producing a stepped semi-hardened product having a joggle in an edge portion, comprising: the first process where a plurality of first sheets made of a fiber-reinforced composite are laminated to each other, heated under a pressure and cooled under a pressure to provide a first flat plate-shaped laminate; the second process where the first flat plate-shaped laminate is softened by heating, placed on a first forming tool and formed by cooling under a pressure to prepare a simple shaped intermediate; and the third process where an edge portion of the simple shaped intermediate is heated under a pressure to form said joggle. A method for producing a preformed structure composed of the stepped semi-hardened product and a simple shaped semi-hardened product is also provided.

Abstract: Method of manufacturing a laminated thermoforming which consists of a thermoformable plastic resin, resin mixtures or a resin matrix as substrate material of the thermoforming and at least one deformable backing material. The pressure and temperature conditions of the thermoforming are adjusted so that the substrate material and backing material are undetachably connected to each other directly by incorporation and/or melting together, and increasing the pressing pressure by additional compressed air support.

Abstract: A metal separator 10 for a fuel cell is configured such that, after forming through-holes 11b and 12b on a first separator member 11 and a second separator member 12, rising wall sections 11c and 12c are provided so as to be spaced apart from formed sections 11a and 12a for introducing a gas by a predetermined distance L, the rising wall section 11c of the first separator member 11 is fittingly inserted into the rising wall section 12c of the second separator member 12 for performing a positional alignment therebeween, and then, the rising wall sections 11c and 12c are folded to be caulked, whereby the first separator member 11 and the second separator member 12 are bonded to each other. A positional alignment between the first separator member 11 and the second separator member 12 become facilitative.

Abstract: The present invention provides a foamed resin laminate sound insulation board capable of exhibiting sound proofing performance, which is free from restrictions of shape, applicable place and weight, thinned as the whole laminated plate to enhance plastic workability such as press work, and provided with sufficient vibration damping performance in a final using state after heating foaming process. This foamed resin laminate sound insulation board 1 is a laminated plate comprising at least an unfoamed foamable resin 3a to be foamed at a foaming temperature by heating and a hard plate 2.

Abstract: The invention relates to a process for producing an enamel baked molded component made from a double-layer plate comprising two cover plates with an intermediate epoxy resin layer that is glued to the cover plates. The process comprises introducing the epoxy resin between the cover plates prior to its polymerization to maintain an adhesive connection between the cover plates and the intermediate layer, while at the same time allowing for deformation of the double-layer plate by deep-drawing in particular without subjecting the cover plates to excessive stress. The epoxy resin that is used polymerized exclusively at the enamel baking temperatures, being coherent but not polymerized when the double-layer plate is deformed, while the enamel layer is baked only after the deformed component is lacquered, whereby said baking occurs at a temperature at which polymerization of the epoxy resin of the intermediate layer also occurs.

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: When manufacturing a foil-wrapped breast prosthesis with a filling consisting of a curable compound, the curing is performed after placing a filled prosthesis bag formed by two joined foil sheets in a mould cavity without closing the mould cavity and maintaining vacuum at least in the beginning of the curing, whereby especially an increased degree of freedom is obtained with respect to shaping the rear side of the prosthesis, so that this, among other things, can be provided with thin edge parts for obtaining good fitting to the body. To ease the mounting of the bag and the accurate positioning of this in the mould cavity, the latter is formed in a first mould part of a shaping tool, which furthermore comprises a tightening frame having a packing, which provides an unambiguously oriented tightening of the bag when this is placed in the mould cavity.

Abstract: A method of making an acoustic device in the form of a loudspeaker drive unit having a resonant panel-form member adapted to provide an acoustic output when excited with bending wave energy, comprising forming a resilient suspension for the panel-form member by molding and simultaneously fixing the resilient suspension to the panel-form member.

Abstract: A stack assemblage of metallic, paper, or paper-like sheets or strips of material secured to one another to define a honeycomb core structure when the assemblage is expanded and flange tabs provided on the opposite edges of said stack. When the stack is expanded, the flange tabs can be deformed into flange orientation on the opposite edges of said stack. The method of fabricating the flange tabs and flanges on the assemblage and the expanded core structure.

Abstract: A machine for continuously manufacturing tape strips having at least at one end a portion folded through an aperture of a workpiece is provided. A tape supply section supplies tape to a tape feed unit which is adapted intermittently supply a first predetermined length of tape through an aperture of a workpiece and a second predetermined length of tape not through an aperture. Work pieces are supplied to and received by a workpiece receiving device adapted to hold the workpiece and position the aperture of the workpiece in the tape traveling path. Tape folders operate to fold a tape towards a fusing member positioned above the workpiece. Tape gripping arms further fold a tape into a fusing member. A tape cutter cuts the tape after a second predetermined length of tape is fed from a tape supply section. Tape gripping arms then operate to eject the finished strap from the machine.

Abstract: A thin abrasion resistant decorative thermosetting laminate of postforming quality is glued to a longitudinal carrier. The carrier preferably consists of a fibre board or a particle board with a rectangular cross section and at least two opposite rounded-off edges. One or more floor strips with the same or different cross section is machined from the laminate clad carrier.

Abstract: A hydroformable frame element is formed from the combination of at least two elements. The at least two elements are designed with a partially overlapping region, with an annular space defined within the overlapping region. The annular space is filled with adhesive, which is then cured to bond the at least two elements together. The adhesive bond is designed to withstand the stresses caused by the hydroforming operation and to retain its strength so that the hydroformed article is then usable as a vehicular frame element.

Abstract: The present invention relates to absorbent articles and non-absorbent articles which comprise at least one improved double-sided soft and elastic material composite. The composites according to the invention may also be breathable. The composites are produced by incrementally stretching a laminate of an elastic layer between two non-elastic cloth-like layers. The non-elastic cloth-like layers tear during stretching such that the elasticity of the laminate after stretching is substantially the same as the elasticity of the film elastic layer.

Abstract: An improved method and apparatus for heat sealing bags having a mandrel with protruding needles for holding the bag material when the material is wrapped around the mandrel. The mandrel has a ridge for allowing easy penetration of an upwardly angled hot blade between the two overlapping ends of the bag. An apparatus composed of three hot blades of which the two outside blades enter the bottom of the bag and expand outward contacting an inner perimeter of the bag when the middle blade moves forward. The blades then retract and the bag is then fused together by pressure bars and cut by heat trimmers.

Abstract: A method of manufacturing a contoured, consolidated cellulosic article, with variable basis weight, is disclosed. The method employs a former to create a mat having a substantially uniform thickness which is pre-pressed to retain its shape. The pre-pressed mat is then machined along at least one surface to result in a desirable contour. The contoured mat is then consolidated within a secondary press. The secondary press preferably includes platens shaped complementarily to the surfaces of the mat.

Abstract: A method for thermoforming a resilient, fluid-filled bladder structure with thermal contact molding is disclosed. The bladder includes two sheets of thermoplastic material that are separated by at least one core formed of two spaced outer layers connected together by a plurality of connecting members. The bladder is formed by bonding the sheets to the core, bonding the sheets to each other around the periphery of the core and forming a sidewall between the sheets in a single mold. A fluid is then inserted into the space bounded by the peripheral bond and the two sheets such that the connecting members are extended.

Abstract: A method is disclosed for temporarily bonding reinforcing sheet metal pieces or other metal pieces to a sheet metal blank for forming at an elevated temperature such as is employed in superplastic forming of suitable aluminum, magnesium, stainless steel or titanium alloys. The pieces are bonded to the blank in locations in which the piece will acquire a desired shape from co-formation with the blank. Suitable water suspendible sodium silicate compositions, such as water glass bond the piece to the blank during high temperature forming and permit removal after forming.

Abstract: A trim component includes a foam backing layer and a foam pad insert laminated between a cover material and a substrate. The foam pad insert provides an area of enhanced cushioning, and has smoothly tapered edges to ensure a smooth surface contour without a visible edge transition on the cover material. The foam pad insert has a lower melting temperature than the foam backing layer, both of which are thermoplastics. A foam pad insert is positioned and fixed on the back surface of the foam backing layer. A substrate material is heated and then laminated and molded with the foam and the cover material. The heat from the substrate partially softens and melts the foam backing layer and the foam pad insert. The partially melted foam pad insert is viscously deformed to form the tapered edges, as dictated by the smoothly varying mold gap spacing of the forming tools.

Abstract: A device and method of use for applying twist-ties onto flexible packages on an assembly line. Each package has a front panel including an exterior surface. Each twist-tie is a strip of material having a first face. The apparatus comprises a glue applicator (e.g., a spray head), a supply (e.g., reel) of twist-tie material, a carrier (e.g., channel shaped head including magnets), and a package support (e.g., conveyor). The package support holds each package at a first station in an orientation whereupon the exterior surface of the front panel is oriented vertically. The carrier is arranged to be oriented in a first horizontal position for receipt of a respective twist-tie thereon so that the first face of the twist-tie is facing upward. The glue applicator applies glue (e.g., sprays hot glue) downward onto the first face of the twist-tie as it is advanced onto the carrier.

Abstract: A trim component (1) includes a substrate (2) and two different cover materials (3, 4), which are not spliced together but are independently adhesively bonded onto the substrate (2) by a hot-melt contact adhesion. The junction (7) is received in a valley (6) of the substrate that is pinched closed using a molding apparatus that includes a horizontally movable pinching stamp (13) which forms a pinching gap (16) relative to a protruding edge (11A) of a fixed mold tool (11). A tucking blade (22) cooperates with a counter-clamping blade (26) to clampingly hold and then press the substrate and junction of the cover sheets into the pinching gap. The tucking blade is then retracted while the pinching stamp pinches closed the pinching gap, to form a tightly closed valley in the substrate with the junction cleanly pinched therein.

Abstract: A method of forming a headliner includes overlaying a cover material onto a multi-layer substrate and at least partially separating the cover material from the substrate during the overlaying. The cover material is clamped separately from the substrate. The overlayed cover material and substrate are then transported into a mold. The substrate is unclamped while the cover material remains clamped, and the cover material and substrate are molded together to form the headliner.

Abstract: A seal for a container opening includes a backing layer and a seal layer for connecting to and covering an opening of the container. A pull-tab forming layer is sandwiched between the backing layer and the seal layer. The pull-tab forming layer has a heat sealable surface joined to the backing layer. An opposite heat resistant surface is joined to the seal layer. A hinge is disposed near the center of the seal that joins the backing layer and the sealed layer wherein the backing layer and at least a portion of the pull-tab forming layer define a pair of pull-tabs extending from the hinge. A method of forming the seal including the pull-tab forming layer and a material blank for forming a plurality of the seals are also described.

Abstract: An EMI shielding enclosure, for an electronic assembly, comprising a ground plane of a printed circuit connected to a shaped EMI shielding cover. The cover results from thermoforming a composite sheet of several layers, including a carrier for a fibrous metal mat that has fibers substantially surrounded by a fiber-coat. Connection of the cover to the ground plane, to form the EMI shielding enclosure, requires the fiber-coat to adhere to the printed circuit in the vicinity of the ground plane.

Abstract: A composite material blank for an orthotic insert. The device is formed of layers of fiberglass and graphite fiber material. A first graphite fiber layer provides the overall structure with increased strength, while secondary graphite fiber reinforcement strips are arranged below the first and fifth rays of the foot to provide additional rigidity and control in these areas. The edges of the graphite fiber layers are recessed inwardly from the edges of the fiberglass layers so as to provide a graphite-free border which prevents cracks from propagating into the graphite fiber layers. The layers are bonded together by heat curing over molds.

Abstract: A method and apparatus for making a formed laminate (20) discloses an applicator (42) for depositing a quick reacting foamable liquid mixture (36) onto a transfer member (38) from which the reacted foam (40) and any foamable liquid mixture that has yet to react is transferred onto a flexible sheet (28). Relative movement of a pair of contoured mold surfaces (74,76) of a mold (68) toward each other compresses the flexible sheet (28) and the foam while the foam is in a transitory state (41) after substantial completion of expansion and before substantial curing has taken place such that it is still viscous. This compression provides a collapsed foam layer (30) and forms the foam as well as the flexible sheet (28) to provide the formed laminate (20). A liner (32) is also provided on the opposite side of the collapsed foam as the flexible sheet.