Abstract: A process for making a composite substrate with cover utilizes heated dies of a forming tool to deform and heat the substrate. The heated substrate is then placed in a marriage tool having a room temperature lower die for receiving the substrate, and a heated upper die. A cover material layer is placed over the substrate and the marriage tool is closed. The cover material includes a heat activatable adhesive and with the marriage tool closed, the heat from the upper die adheres the cover material layer to the substrate while the room temperature die cools the substrate. In this way, when the marriage tool is opened, the composite structure can be removed without deformation.

Abstract: A method for manufacturing pre-stressed piezoelectric actuators using a pre-curved piece of ceramic is provided. An adhesive, preferably a polyimide, is disposed between a metal pre-stress metal layer and a pre-curved PZT ceramic. The entire composite structure is heated to a temperature above the melting point of the adhesive material and then subsequently cooled to allow the adhesive layer to set. As a result of the difference in thermal contraction rates of the materials, the pre-curved PZT ceramic is compressively stressed. This pre-stressing provides a piezoelectric actuator which is durable, and produces a higher displacement than a conventional piezoelectric actuator.

Abstract: An apparatus and method provide for the assembly of a multiply shaped fiber preform, the apparatus using a shaping tool having the shape of the desired part, and one or more secondary location tools, can be positioned on the shaping tool, so as to simulate a flat shape. The location tools include a number of upwardly extending location pins, such that a number of plies can be assembled in a vertical stack using the pins to assure ply to ply accuracy and orientation. After assembly, the plies are engaged in a localized portion of the assembly so as to hold the plies in register, with the secondary tools then removed and the plies then formed to shape over the tool surfaces. Utilizing the apparatus and method of the invention maintains multiple plies in register during the assembly and forming process to assure part reproducibility, in an automated process.

Abstract: A process for forming flexible cutting line for use in rotary vegetation trimmers of the type having two or more monofilament lines mounted on a common spool. The line produced by the process of the present invention defines two monofilament strands joined together in a side by side relationship by a severable bond. The process includes the steps of extruding one or more pairs of molten monofilament strands in proximate disposition, directing the strands together in a cooling quench bath, pulling the strands in an adjacent abutting disposition through the quench bath to initiate the crystallization and bonding together of the two strands, concurrently stretching and heating the bonded strands to effect parallel alignment of the molecular chain in the strands, heating the strands in a relaxed disposition, wetting the strands and spooling the wetted strands for storage and transportation.

Abstract: A pad including thermal insulation and heat sink areas. The pad includes a plurality of layers of metal foil forming a stack with the layers arranged one above the other, the stack including at least one heat sink area and at least one insulating area adjacent to the heat sink area, the layers providing better heat conduction in the vertical direction at the heat sink area than at the insulating area. At least one of the layers includes a plurality of embossments therein separating the one layer from an adjacent one of the layers in the insulating area. The pad can include a single insulating area surrounded by a heat sink area and a black coating can be provided on selected portions of the layers to improve heat radiating characteristics of the pad. For instance, the heat sink area can be coated with the black coating to radiate heat away from the pad at a desired location.

Abstract: A process for the manufacture of an aircraft stowage container, comprising a bottom member A, a top member D, at least two side wall members B, C, and two plane end wall members 1. Said members are essentially rigid and plane. Additionally an essentially rigid closure flap member 3 may be provided. The process comprises the steps of preparing at least two layers of prepregs impregnated with a curable thermosettings for forming the top, bottom and side wall members or the U-shaped surround. Between at least two of said layers of prepregs 6 a honeycomb construction material 7 is interposed in a manner that several regions spaced apart from each other are defined by said honeycomb material thereby defining folding or bending regions. Then the layers of prepregs are bent or folded by applying them over a mould 5, and they are cured afterwards in an autoclave by beat application to a cured composite component 2.

Abstract: A process for producing a fiber-reinforced thermoplastic resin molded article including: (a) projecting a sheet-holding member from a cavity face of a lower mold towards a cavity face of an upper mold, (b) placing a heated fiber-reinforced thermoplastic resin sheet on the sheet-holding member, (c) closing the upper and lower molds, (d) in the step of closing the upper and lower molds, putting the sheet-holding member into the lower mold before the cavity face of the upper mold contacts with the resin sheet, (e) maintaining the upper and lower molds in a closed state, and (f) opening the upper and lower molds and removing the molded article. A fiber-reinforced thermoplastic resin molded article which has a good surface appearance and, if any, whose protrusions such as ribs and bosses are sufficiently filled with thermoplastic resin and reinforcing fibers, can be produced, without using an additional thermoplastic resin sheet and without repeating the molding process.

Abstract: A composite hot drape vacuum forming method and apparatus. The apparatus includes an elongate vacuum chamber (12) having a lid (14) and a housing (16). An inflatable seal (26) is disposed between the lid (14) and the housing (16). Inflation of the inflatable seal (26) creates on airtight vacuum chamber. A heating blanket (36) is located in the bottom of the vacuum chamber (12). An inflatable bladder (28) is located on top of the heating blanket and extends approximately over the length of the vacuum chamber. The interior of the inflatable bladder is in fluid connection with the exterior of the vacuum chamber. Composite charges (40) are placed within the vacuum chamber on top of the vacuum bladder (28). Lay-up mandrels (42) are placed on top of the unformed composite charges and the vacuum chamber is closed and sealed. The composite charges (40) are heated using the heating blanket (36). The interior of the vacuum chamber is then evacuated.

Abstract: A laminated filter material may be used in seamless filter bags in order to increase the strength and filtering ability of a pressurized filter system.

Abstract: A molded, self-supporting, composite part or panel for automotive and similar applications comprises a vapor impervious wood fiber filled polymeric (preferably polypropylene) sheet adhered to one major face of a corrugated paperboard medium and a layer of fibrous insulation (preferably glass fiber) or a second wood fiber filled polymeric sheet adhered to a second major face of the corrugated paperboard medium. The sheet and corrugated medium provide the structural strength for the composite and the fibrous insulation, when used, provides the composite with good sound absorption properties. The wood fiber filled polymeric sheet is formed during the molding process from a wood and polymeric fiber sheet. The heat and pressure of the molding process cause the polymeric fibers to melt and flow about the wood fibers to form the wood fiber filled sheet and bond the sheet securely to the corrugated medium.

Abstract: Thermoplastic, thermoshapable composite laminate bars, an orthopedic brace using the shaped composite bars as integral components, and a method of thermoshaping the composite bars for use as fitted components in the orthopedic brace are provided. The composite bars contain multiple fiber layers oriented in at least two directions with respect to the bar length to provide high flexural and torsional strength. The novel method of thermoshaping yields improved results over prior thermoshaping methods by providing an uncomplicated shaping capability while maintaining the structural and mechanical properties of the composite bar.

Abstract: A wooden tube made up of tubular layers of wood veneer and the method of making it in which the various tubular layers are made from flat sheets of wood veneer having the grain in one layer extending longitudinally and the grain in an adjacent layer extending circumferentially of the tube so that the grain in adjacent layers extend transversely of each other with all joints extending in the direction of the wood grain being edge to edge butt joints and all joints extending transversely to the wood grain being interlocking finger joints and with adjoining tubular layers being bonded to each other to form a unitary tube.

Abstract: A method for producing an interior a product comprising a corrugated cardboard base formed into a predetermined shape and a decorative skin layer laminated to one side of the cardboard base. Using a hot-press, a substantially planar cardboard base comprising a corrugated core and liners laminated to both sides of the core through thermoplastic resin films is formed into a predetermined shape by heat and pressure at a temperature high enough for remaining heat to be sufficient to melt a hot melt adhesive on the surface of the cardboard base after removal of the formed cardboard base from the hot press but not so hot as to scorch the paper of the cardboard base. The formed cardboard base is then taken out of the hot press and transferred into a cold press, thereafter a decorative skin is put on the surface of the formed cardboard base through a hot melt adhesive.

Abstract: A method of forming fabric for making foam-in-place molded articles such as preferably seat cushions. A film is secured to a frame and tacked by adhesive to a piece of fabric, not secured to the frame, that forms the outer covering of the seat cushion for permitting the fabric to move relative to the film during forming to enable fabrics which cannot stretch a considerable amount to be used. To form the fabric, the film and fabric are placed in a female mold and the film and fabric are drawn into a cavity of the mold and against a contoured surface in the cavity forming a recess in the film and fabric. To counteract compressive stresses in the fabric during forming, the frame can have one or more fabric tensioners that selectively apply tension to the fabric during forming. To mold the cushion, a foam is poured into the recess and allowed to cure until it hardens into a foam core and bonds with the film.

Abstract: A method of forming a multipole magnet wherein two backing sheets of paper or film material are screen or stencil printed with an ink containing magnetic particles and a carrier material to provide respective complementary patterned areas thereon, the patterned areas of ink are cured or dried, the respective ink patterns are magnetized using a magnetic field perpendicular to a plane of the backing sheets, and the sheets are combined into a laminate wherein the patterned areas are located between the two sheets.

Abstract: Disclosed is a method for manufacturing a composite pad from stock made of a relatively thin, sheet-like first layer, a relatively thin, sheet-like second layer and a relatively thick layer of an elastic, cushioning material sandwiched between the two. The outer layers are made of material, such as heat sealable material, that forms a seal under predetermined conditions. The pad is manufactured by first forming a sealed perimeter from the stock using a sealing tool and then using the same tool to separate the pad from the adjacent stock while simultaneously orienting the seal away from the side of the pad which will contact the wearer of a brace into which the pad is fitted.

Abstract: A method of manufacturing molded goods includes using paper and pulp sheets as materials for forming a plurality of molded goods at one time using a press molding machine. A plurality of predetermined molding sections of the paper or pulp sheet is subjected to press molding. The upper and lower forming dies of the press molding machine are respectively equipped with a plurality of cores and cavities which correspond in shape to the mold goods in number and shape. Quasi-broken portions are provided between a plurality of adjacent predetermined molding sections before the paper or pulp sheet is subjected to heating and pressing by the press molding machine for molding.

Abstract: To form a prebonded composite structure, a laminate composite is prepared by positioning a first layer of heat-activated adhesive between a first fabric layer and a second side of a pad and a second fabric layer is positioned adjacent a second side of the pad. The laminate composite is heated to produce a heated laminate composite and the heated laminate composite is positioned between an upper mold and a lower mold. The laminate composite is compressed between the upper and lower molds, thereby compressing the first layer of heat-activated adhesive between the pad and the first fabric layer. In one application, dielectric heat is applied to the laminate composite during the step of compressing the laminate composite.

Abstract: A method of producing a printed article includes the following steps: providing a first web of polyethylene upon which a pattern has been printed; providing a second web of plastics material from which the article is to be formed, one of the first or second webs having a heat seal lacquer applied thereto; passing the first and second webs through a pair of heated rollers to cause the heat seal lacquer to become tacky; directing the first and second webs in adjacent overlying relation to a vacuum forming machine including a mold and applying heat and vacuum in the vacuum forming machine to cause the first and second webs to conform to the shape of the mold to produce the printed article, wherein the application of heat in the vacuum forming machine activates the heat seal lacquer to adhere the first and second webs together.

Abstract: In accordance with the present invention, there is provided a process for preparing thermoplastic elastomer laminates which comprises placing a thermoplastic elastomer foamable sheet in an unexpanded state containing a polyolefin resin, an ethylene/.alpha.-olefin copolymer rubber and a foaming agent onto the back of a thermoplastic elastomer sheet containing a polyolefin resin and an ethylene/.alpha.-olefin copolymer rubber, heat fusion bonding both sheets to each other, and heating the resulting laminated sheet to expand the thermoplastic elastomer sheet containing the foaming agent.

Abstract: A system and method for reducing the occurrence of undesirable deformations (e.g., wrinkling) in a reinforced thermoformable workpiece. The reduction in undesirable deformations is achieved by increasing the buckling resistance of the workpiece by employing a supplemental reinforcing structure. The reinforcement, in combination with a pair of shaping diaphragms, increase the effective buckling resistance applied to the workpiece during the fabrication of a composite product. The method includes forming a workpiece from a plurality of layers of a thermoformable material, and applying to at least one side of the material an external reinforcing structure to form a reinforced workpiece having a top side and a bottom side. At least one of the top or bottom sides of the reinforced workpiece is placed in contact vith a diaphragm, thus forming a shaping assembly.

Abstract: Absorbent articles having side panels that provide inflected barrier cuffs which promote better containment and fit. The absorbent article has a front waist region, a rear waist region, a crotch region and a pair of longitudinal edges. The absorbent article further comprises a chassis including a pair of longitudinally extending side panels, each of the side panels having a front ear flap section; a barrier cuff section having a first end edge located longitudinally inboard of the front ear flap section; a second end edge located in the rear waist region; a proximal edge and a distal edge; spacing means joined with each barrier cuff section; and closing means for securing at least a portion of the barrier cuff section juxtaposed the first end edge to the absorbent article inboard of the proximal edge. The distal edges are unsecured to any underlying structure of the absorbent article in the front and rear waist regions such that the distal edges form the longitudinal edges in the front and rear waist regions.

Abstract: A shingle is provided that is especially adapted for application to hips or ridges of a roof. In a preferred embodiment, the shingle is a laminated multi-layer shingle, bent or curled into a preformed shape that is reasonably close to the shape that it will have in the installed condition. The shingle layers are connected together in more than one zone, or in one large zone after sliding relative to one another as the shingle is bent or curled. Preferably, such connection is by means of an adhesive.

Abstract: A method of forming a lightweight, contoured, structurally stable, self-supporting laminate comprises laying down, in succession, a finish lamina, a first heat activated adhesive, a first thermoformable scrim lamina, a second heat activated adhesive, a high density polymeric foam lamina, a third heat activated adhesive, and a second thermoformable scrim lamina thereby forming an unbonded laminate. This unbonded laminate is then uniformly heated in an oven to a temperature sufficient to make the adhesives bondable thereby forming a heated, substantially unbonded laminate. This heated, substantially unbonded laminate is then quickly transferred to a contoured die press and permanently bonded and formed, under pressure. The laminate is permanently bonded utilizing the residual heat in the laminate to form a contoured, structurally stable, self-supporting, impact resistant laminate.

Abstract: The present invention is directed to an apparatus and an associated method for achieving alignment between an image on a film and a lenticular material that is to be bonded to the film to permit the image to be viewed in 3D. The apparatus imparts a controlled bending of the lenticular material over the film such that the slight differences in length between the lenticular material and the film, caused by the bending, adjusts for changes in the line spacing of the lenticular material and or in the spacing of the image segments. Other embodiments of the invention provide for a controlled stretching of the film along its length and from side-to-side to again compensate for variations in the line spacing of the lenticular material or spacing of the image segments.

Abstract: The present invention provides a unique and rapid method of producing a laminate foam or matted yarn article having permanent, pliable, decorative embossing lines or patterns which produce a relief-like article such as an embossed seat cushion or cover or the like.

Abstract: A method of bonding a contoured seat cover with a first surface to a seat cushion with a second surface is provided which includes the steps of coating the second surface with a heat-activated adhesive, placing a flexible planar heating member between the first and second surfaces, pressing the first and second surfaces together against the heater with a force of one to five pounds per square inch, heating the adhesive with the heating member, removing the heating member while the first and second surfaces are pressed together, and allowing the adhesive to solidify and then relieving the pressure between the seat cover and the seat cushion.

Abstract: A coreless filter comprises a pleated, spirally wound loop of material disposed in a housing. The loop includes a layer of filter material, such as a membrane filter, interposed between two support layers.

Abstract: The present invention provides a female component for engaging a complementary hook component in a refastenable fastening device. The female component of the present invention 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. Each zone has certain of the desired individual characteristics for entangling and holding the hooks of the mating hook component. 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 for providing a foundation for the entanglement and spacing zones.

Abstract: A method for embodying a display cell with a counter-electrode contact pickup. Contact blocks 12 are separated from counter-electrode contacts 20 by passivation film 22. The electrodes linked between the counter-electrode and the contacts 20 are obtained by calcining the glue of the blocks so as to render them conductive by using a laser beam 30. In addition, the passivation film 22 is perforated by using the laser beam 30. This method finds particular application in the embodiment of liquid crystal display screens.

Abstract: A coreless filter comprises a pleated, spirally wound loop of material disposed in a housing. The loop includes a layer of filter material, such as a membrane filter, interposed between two support layers.

Abstract: A method of manufacturing a lens for use as a part of an aircraft including the steps of fusion bonding a sheet of acrylic to a sheet of polycarbonate to form a sheet of laminate, cutting the laminate into a blank having a configuration required by the ultimate lens configuration, heating the blank and forming it around a mold to provide a three dimensional lens body of desired size and configuration having an uninterrupted circumferential edge and having an inner polycarbonate surface and an outer acrylic surface, applying a narrow strip seal to the lens body inner surface in a narrow strip portion adjacent substantially the full circumferential edge thereof in order to bond the strip seal to the lens body, shaping the circumferential edge of the lens body around substantially the full circumferential edge thereof, and providing bushings in the lens body and strip seal so the bushings are spaced around the circumferential edge as a means of securing the lens to an aircraft.

Abstract: A method of fabricating a structural member having a stiffener bead therein. Prepreg plies or layers of high tensile strength fabric are laid up on a conformable caul plate. A rubber-like plug is prefabricated to the shape of the stiffener bead and is urged into a stiffener bead cavity of the caul plate by a metal tool to sandwich the prepreg plies between the caul and the plug. The caul and the plug cooperate to cause the prepreg plies to conform to the desired shape of the stiffener bead.

Abstract: A workpiece of a fiber-containing composite material is formed in a kinematically admissible manner by applying a tension loading to the workpiece in a transverse direction and passing the workpiece in the transverse direction through apparatus having a bending roller extending in the longitudinal direction over substantially the entire length of the workpiece. The workpiece is formed over the bending roller by introducing a net bending deformation into the workpiece and progressively propagating the bend transversely through the workpiece as the workpiece is moved in the transverse direction. The transverse laminar length of the workpiece remains substantially unchanged during the forming process. Preferably, the workpiece is contained within a vacuum bag during the forming operation.

Abstract: During the first stage, the elements of the ski structure are assembled according to an essentially rectilinear beam, including at least one thermofusible film in at least one gripping zone near either the front or back end of the structure. During the recovery stage after the first stage, this gripping zone is heated to a temperature slightly higher than the softening temperature of the thermofusible film and the heated gripping zone can be shaped in the form of a spatula and/or of the heel.

Abstract: Stampable reinforced thermoplastic sheet, at least one face of which comprises, from the outside to the inside, at least three successive layers abc, in which:a is a matrix comprising a thermoplastic resin reinforced by at least two fillers of different nature and/or type chosen from fillers of the lamellar type and of the spherical or substantially spherical type,b is an interfacial binder chemically compatible with the thermoplastic resin of a and having, with respect to the latter, a lower viscosity at the temperatures at which the sheets are produced and used, andc is a reinforcement comprising a needled glass mat.Articles obtained from the sheets by stamping.

Abstract: Process an equipment for the production of an expanded honeycomb core from strips (10) coated at uniform intervals with strips of adhesive (6), in which the strips (10) with their adhesive strips (6) parallel and in staggered positions are stacked on top of one another and adhesively bonded together under pressure and if necessary at an elevated temperature, the stack (40) so formed being subsequently expanded, consists in the following: a strip (10) passes over a position detector (24), which from the adhesive strips (6) determines its position relative to a first end (P) of a stack (40), and which controls a positioning drive (25) and a cutting device (26). The positioning drive (25) positions the strip (10) relative to the stack (40) at its end (P), and the strip (10) is held fast.

Abstract: A process for manufacturing a foamed laminate, which has a plurality of colors, alternating ridges and ridge-confined grooves, includes the steps of (a) superimposing an upper foamed plate having colored stripes, on a lower foamed plate having a single color; (b) pressing the upper and lower foamed plates using an upper and a lower press die to form a laminate, each of the press dies having ridges and ridge-confined grooves; (c) cutting off portions of the upper foamed plate formed at the ridges thereof in order to expose the lower foamed plate; and (d) cutting projections at the lower foamed plate so as to make the lower foamed plate flat.

Abstract: A method for forming stabilized preforms for complex composite articles is disclosed using a solid meltable uncatalyzed thermosetting resin as the stabilizing agent. The resin is applied to each layer of the preform and heated to melt the resin and bond the layers together. After cooling, the resin resolidifies but does not set and thereby holds the layers in the desired preform shape. The layers can be first formed into a flat sheet as a raw material from which shaped preforms can be made by cutting the sheet into sections which are placed over a mandrel and reheating to thereby remelt the solid resin to allow the preform to conform to the shape of the mandrel. Utilizing this process allows complex composite parts to be easily preformed and assembled prior to placement in a mold for resin injection molding, without inhibiting part strength as the resin is compatible with the injection resin and is cocatalyzed by the catalyst contained in the injection resin.

Abstract: A preheatable scrim and method of use for bonding together multiple layers of materials to form a laminate. The scrim includes a carrier layer which is impregnated with an adhesive having a melting point such that it can set and hold a bond. The scrim is preheated to its activation temperature and sandwiched between the materials layers. The sandwich is pressed together to bond the layers.

Abstract: A system for forming an article includes an apparatus for stacking successive sheets of a polymer mixture and selectively irradiating each sheet with an electron beam deflected to trace the configuraiton of an incremental heighth of the article. The polymer mixture may include a polymer resin mixed with a reactive diluent and, if required, an initiator. The stacked sheets form a matrix which supports the article as it is being shaped. After integration of all incremental heighths of the article, heat or chemical dissolution is employed to remove the matrix. The sheets may be a laminate of a stratum bonded to a substratum. The substratum is easily compressed under heat to reference the level of the upper surface of the sheet irrespective of thickness variations of the sheet. To compensate for beam intensity absorption, the substratum is formulated with increased sensitivity. Successive sheets are heated while being transported to a platen which is positioned beneath an electron gun.

Abstract: A laminated gasket assembly and method of making same is disclosed. The laminated gasket assembly comprises first and second sheets, each having a thin metallic layer having a thin elastomeric coating on at least one major surface, and an elastomeric layer interposed between, and joining, the sheets, with first and second thin elastomeric coatings facing outwardly in opposite directions. The gasket assembly defines at least one elevated pressure service opening therethrough. The sheets and layers are laminated and define an embossment around a service opening, with the elastomeric layer being conformed to the embossment.

Abstract: A prestressed thermoformed panel, comprising an inner thermoplastic layer having fine grooves on the outer surfaces thereof, and outer fiber-reinforced thermosetting layers bonded to the outer surfaces of the inner layer. The grooves of the inner layer are of a size, pattern and orientation similar to that of the fibers of the thermosetting materials so that at least some of the fibers are positioned in the grooves to enhance the strength of the panel. In the method of forming the panel, the inner and outer layers are heated to approximately the fusion temperature of the thermoplastic material while applying inward pressure on the outer layers in the direction of the inner layer to bond them thereto. The pressure is less than the extruding pressure of the thermoplastic material. Thereafter, the thermosetting outer layers are cured, and the inward pressure on the outer layers is maintained until the temperature is at least 50.degree. F. below the fusion temperature of the thermoplastic material.

Abstract: A formed panel construction and method are provided for portable acoustic partitions of the type which are assembled and configured to create workstations in open office plans. Each partition panel includes a freestanding, open frame with a pair of formed cover panels detachably connected to the opposite sides of the frame to enclose the partition. Each cover panel comprises a laminated composite sheet, which includes a sound absorbant backing sheet constructed from heat fusible fibers, and an overlying upholstery sheet with a finished exterior surface. The composite sheet is heated to soften or plasticize the heat fusible fibers, and is compressed and molded while heated to a predetermined geometrically solid shape, such as a five-sided panel having a flat face and four marginal flanges extending at an angle therefrom.

Abstract: The present invention discloses a method for laminating at least two polymer films. An intermediate assembly 40 is made comprising an adhesive film 20 and a dielectric polymer film 12. The method comprises the steps of: selecting an adhesive film 20 with a melting point T.sub.1, the adhesive film having inner and outer major surfaces 22, 24; selecting a polymer film 12, with a melting point T.sub.2, where T.sub.2 >T.sub.1, the polymer film having inner and outer major surfaces 14, 16; subjecting the inner surface 14 of the polymer film 12 to a high voltage electric discharge to form a treated inner surface; heating the polymer film 12 having the treated inner surface to a temperature greater than T.sub.1 ; aligning the inner adhesive surface 22 and the inner treated polymer surface 14 in opposed facing relationship; applying pressure to urge the films 12, 20 relatively together; and heating the pressed together films to a temperature greater than T.sub.

Abstract: A method for forming stabilized preforms for complex composite articles is disclosed using a solid meltable uncatalyzed thermosetting resin as the stabilizing agent. The resin is applied to each layer of the preform and heated to melt the resin and bond the layers together. After cooling, the resin resolidifies but does not set and thereby holds the layers in the desired preform shape. The layers can be first formed into a flat sheet as a raw material from which shaped preforms can be made by cutting the sheet into sections which are placed over a mandrel and reheating to thereby remelt the solid resin to allow the preform to conform to the shape of the mandrel. Utilizing this process allows complex composite parts to be easily preformed and assembled prior to placement in a mold for resin injection molding, without inhibiting part strength as the resin is compatible with the injection resin and is cocatalyzed by the catalyst contained in the injection resin.

Abstract: A device and method for manufacturing a layered article having a beveled edge and including a flexible outer layer and an internal elastomeric layer. The device comprises independently operative bearing surfaces wherein a first surface exerts a first pressure on the article body and a second surface exerts a second pressure on the article edge.

Abstract: The method is one of producing multi-ply laminates incorporating an exposed veneer in quality wood or cork, and involved bonding the veneer (1) to a thin flexible thermoplastic film (2) by way of a layer of hot melt adhesive (3). The same laminate can be reinforced to enable its use in manufacturing sewn goods, such as bags and acessories, by ading a tough, close-woven backing fabric (20), bonded to the back of the film (2) in similar fashion via a further layer of adhesive (3), which provides the strength necessary to take a heavy stitch when sheets are sewn together.

Abstract: There are provided laminate structures comprising a reinforcing fibrous mat integrally bonded to a resilient fibrous batt. The mat is preferentially a porous mat of resin-bonded chopped glass fiber. The batt is preferentially a porous batt of natural or synthetic fibers. Preferentially, the laminate comprises a core of resilient fibrous batt sandwiched between two facing sheets of reinforcing fibrous mat, with a decorative cover layer being laminated to the exterior surface of one reinforcing fibrous mat, the whole being bonded together by a thermoset binder into a unitary structure.

Abstract: One method of forming a workpiece made of thermoformable material includes the steps of: (a) supporting a raw workpiece on a suspension tray; (b) moving a pair of relatively hot forming dies into position above the workpiece; (c) closing the hot forming dies against the workpiece to heat the workpiece and to form and shape the workpiece into the desired configuration; (d) opening the hot forming dies and removing the hot forming dies away from the workpiece; (e) moving a pair of relatively cold forming dies into position above and below the workpiece; (f) closing the cold forming dies against the workpiece to cool the workpiece while maintaining the workpiece in the desired configuration; and, (g) opening the cold forming dies and removing the finished workpiece form the suspension tray. Other methods are also disclosed.