To Form Dished Or Receptacle-like Product Patents (Class 156/224)
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Patent number: 6801600Abstract: A scattered ray removal grid that has an overall shape of constant spherical curvature. The scattered ray removal grid has radiation absorbing portions arrayed in a lattice configuration and radiation non-absorbing portions made of thermoplastic resin disposed between the radiation absorbing portions and can therefore be easily produced to have an overall spherical shape at low cost.Type: GrantFiled: March 31, 2003Date of Patent: October 5, 2004Assignee: Fuji Photo Film Co., Ltd.Inventor: Katsuhiro Kohda
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Patent number: 6761785Abstract: Amethod for constructing a composite structure is disclosed. The method comprises four steps. Step one calls for coupling a flexible layer to a base, where the flexible layer has a working surface and an underside surface. Step two requires coupling at least one support element to the underside surface of the flexible layer. The next step calls for coupling at least one adjustable element to the support element for adjusting the position of the flexible layer. The last step requires configuring the flexible layer to a configuration suitable for constructing the composite structure. More specifically, the flexible layer may have internal reinforcing elements for added strength and durability.Type: GrantFiled: September 11, 2001Date of Patent: July 13, 2004Assignee: Northrop Grumman CorporationInventors: David E. Sherrill, Kendall G. Young
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Patent number: 6761787Abstract: A bag that is made silent for purposes of using the bag on a studio set in movies, television, and other live and pre-recorded settings, where set props are needed to recreate real life situations for dramatization, but where real life sound that is created by bags interferes with the recording, broadcasting, or amplification of the dramatic performance. The bag is able to maintain real or imaginary brand labels for either product placement or true-to-life dramatization applications.Type: GrantFiled: May 15, 2002Date of Patent: July 13, 2004Inventor: Timothy Schultz
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Patent number: 6695942Abstract: A method of manufacturing motor car steering wheels with an external shell made of composite materials, which comprises preparing a pile of sheets of composite materials, hot molding thereof for obtaining respective half-shells with a shape corresponding to that of respective halves of the steering wheel being manufactured, mechanical flattening of the front surfaces of the two half-shells, applying the two half-shells to opposite parts of a steering wheel body formed by a metallic core covered by resin, and mutual fixing of the two half-shells along said front surfaces. After flattening, the front surfaces of the two half-shells are mechanically worked to form respective complementary teeth which can be male-female coupled when the two half-shells are applied around the steering wheel body.Type: GrantFiled: June 1, 2001Date of Patent: February 24, 2004Assignee: Breed Automotive Technology, Inc.Inventor: Giuseppe Testa
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Publication number: 20040026014Abstract: The method includes the stages of gluing of a plurality of layers of sheet material (2, 3, 4); and stamping of all the layers (2, 3, 4) together; with sticking together of the previously glued zones being carried out at the same time as the stamping of all the layers (2, 3, 4). The machine includes gluing stations (12) (2, 3, 4); and a stamping station (13) which includes a pair of pressing elements, which stamp and stick together said previously glued layers. The laminar element is formed from a plurality of layers of sheet material (2, 3, 4) and can include one or several cavities (5) of polygonal profile, or else said layers are of sinusoidal profile. A higher manufacturing output of the laminar layer is achieved and it permits the forming of a laminar element with cavities or undulations of any desired shape, without limitation on the thickness of the layers.Type: ApplicationFiled: June 16, 2003Publication date: February 12, 2004Inventor: Jaume Teixidor Casanovas
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Patent number: 6594878Abstract: A scattered ray removal grid that has an overall shape of constant spherical curvature. The scattered ray removal grid has radiation absorbing portions arrayed in a lattice configuration and radiation non-absorbing portions made of thermoplastic resin disposed between the radiation absorbing portions and can therefore be easily produced to have an overall spherical shape at low cost.Type: GrantFiled: January 27, 2000Date of Patent: July 22, 2003Assignee: Fuji Photo Film Co., Ltd.Inventor: Katsuhiro Kohda
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Patent number: 6471808Abstract: A method of manufacturing a motor car steering wheel with an external shell made of carbon fibers begins with preparing a pile of sheet materials which is then hot molded to yield respective half-shells with a shape corresponding to that of respective halves of the steering wheel being manufactured. Next comes mechanical flattening of the front surfaces of the two half-shells, followed by mounting of the two half-shells above and under a steering wheel body formed by a metallic core covered by resin. The steering wheel body has lateral profile members which act as fixing supports for the two half-shells.Type: GrantFiled: February 23, 2001Date of Patent: October 29, 2002Assignee: Breed Automotive Technology, Inc.Inventors: Giuseppe Testa, Adolfo Ridolfi, Paolo Vian
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Patent number: 6472046Abstract: A biaxially oriented polyester film to be laminated onto a metal plate and molded, (A) which comprises a copolyester comprising (a) terephthalic acid in an amount of 82 to 100 mol % and 2,6-naphthalenedicarboxylic acid or a combination of 2,6-naphthalenedicarboxylic acid and other dicarboxylic acid in an amount of 0 to 18 mol % of the total of all dicarboxylic acid components and (b) ethylene glycol in an amount of 82 to 100 mol % and cyclohexanedimethanol or a combination of cyclohexanedimethanol and other diol in an amount of 0 to 18 mol % of the total of all diol components, having (c) a glass transition temperature of 78° C. or more and (d) a melting point of 210 to 250° C., and containing (e) porous silica particles with a pore volume of 0.5 to 2.0 ml/g which are agglomerates of primary particles having an average particle diameter of 0.001 to 0.1 &mgr;m; and (B) which has the following relationship between the highest peak temperature (Te, °C.Type: GrantFiled: August 18, 1999Date of Patent: October 29, 2002Assignee: Teijin LimitedInventors: Koji Kubo, Hirofumi Murooka, Masahiko Kosuge, Hideshi Kurihara
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Patent number: 6452091Abstract: The peeling of a thin-film single-crystal from a substrate is carried out so that the directions of straight lines on the single-crystal surface made by planes on which the single-crystal is apt to cleave are different from the front line direction of the peeled single-crystal. This single-crystal is used in a solar cell and a drive circuit member of an image display element. A method is provided which prevents a decrease in quality and yield of a single crystal layer when it is peeled from a substrate. A flexible solar cell module having a thin film single-crystal layer is made so that its flexing direction is different from the single-crystal's cleaving direction. Thus, a thin-film single-crystal solar cell module having excellent durability and reliability due to a lack of defect or cracking during production and use, and a method for producing the same, is provided.Type: GrantFiled: July 12, 2000Date of Patent: September 17, 2002Assignee: Canon Kabushiki KaishaInventors: Katsumi Nakagawa, Takao Yonehara, Yasuyoshi Takai, Kiyofumi Sakaguchi, Noritaka Ukiyo, Masaaki Iwane, Yukiko Iwasaki
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Patent number: 6440564Abstract: The invention relates to a relatively soft, largely planar, though three-dimensional product, obtainable by means of an embossing tool for converting a relatively soft, planar starting product as a result of embossing to the extent that an embossing pattern exists which comprises a plurality of “hinged parallelograms” that are limited by lines of compressed material such that when tractive forces are applied, this hinged parallelogram structure behaves like a pantograph and a secondary bulk is superimposed as a result of a stretching process on the primary bulk produced by the embossing.Type: GrantFiled: February 7, 2000Date of Patent: August 27, 2002Assignee: SCA Hygiene Products GmbHInventors: John Dunn McLain, Brian Hunt, George Rutherford
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Publication number: 20020007902Abstract: A method of manufacturing a condiment cup teaches the use of a thermoplastic material having a means for resisting oxygen permeation. The thermoplastic material is then thermoformed into the condiment cup having a base and an upwardly extending sidewall that together define a storage space, the upwardly extending sidewall terminating in a perimeter lip that defines an opening for accessing the storage space. The condiment cup further includes a horizontal attachment arm extending outwardly from the perimeter lip. The horizontal attachment arm is then bent downwardly to form an attachment arm extending downwardly from the perimeter flange.Type: ApplicationFiled: October 1, 2001Publication date: January 24, 2002Inventor: Gary Nance
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Patent number: 6288324Abstract: In order to ensure long-term reliability when a photovoltaic element is bent or curved to be deformed: (1) In a method for manufacturing a solar cell module having a photovoltaic element encapsulated with a resin on a support member, the step is adopted which forms a bent portion in the photovoltaic element and in the support member, wherein the formation of the bent portion is performed while reducing a working pressure in the normal direction to a surface of the photovoltaic element; and (2) In a solar cell module comprising a photovoltaic element comprising at least one photoactive semiconductor layer on a flexible substrate, at least a part of the flexible substrate is subjected to tensile deformation in the direction parallel to a surface of the substrate with a strain less than a critical strain to lower the fill factor of the photovoltaic element, whereby the photovoltaic element is deformed.Type: GrantFiled: November 7, 2000Date of Patent: September 11, 2001Assignee: Canon Kabushiki KaishaInventors: Ayako Komori, Kimitoshi Fukae, Akiharu Takabayashi, Toshihiko Mimura, Masahiro Mori, Takeshi Takada
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Publication number: 20010006011Abstract: A method of manufacturing a motor car steering wheel with an external shell made of carbon fibers, which comprises preparing a pile of sheet materials, hot molding thereof for obtaining respective half-shells with a shape corresponding to that of respective halves of the steering wheel being manufactured, mechanical flattening of the front surfaces of the two half-shells, mounting of the two half-shells above and under a steering wheel body formed by a metallic core covered by resin. The steering wheel body has lateral profiles which act as fixing supports for the two half-shells.Type: ApplicationFiled: February 23, 2001Publication date: July 5, 2001Inventors: Giuseppe Testa, Adolfo Ridolfi, Paolo Vian
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Patent number: 6238507Abstract: A trim panel for use in automotive trim applications is made from a laminate of a thermoformable support layer and an A-side layer made of vinyl or cloth or similar material. The laminate is thermoformed to impart permanently the contour of a rigid substrate to which the panel will be attached. The support layer retains the desired contour without the use of other materials. The support layer is made of an intermediate layer and a bottom layer of thermoformable foam. The foam layers have different densities to allow selection of the hand or touch of the A-side layer.Type: GrantFiled: March 25, 1999Date of Patent: May 29, 2001Assignee: Simco Automotive Trim, Inc.Inventors: Vincent H-H Jones, David L. Simon
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Patent number: 6235138Abstract: The present invention relates to a process for the production of a polyurethane foam backed instrument panel. This process comprises slicing a free-rise bun of polyurethane foam to form a skived polyurethane foam, bonding the skived foam to a skin material to form a laminate, optionally, rolling the foam/skin laminate, thermoforming the foam/skin laminate into an instrument panel skin, positioning the instrument panel skin into the cavity of a mold, positioning a retainer into the core of the mold, adhering the retainer to the laminate by placing an adhesive film onto the retainer, closing the mold to apply heat and pressure, and removing the resultant instrument panel from the mold. Suitable polyurethane foams for the present invention may be flexible foams or semi-rigid foams. This invention also relates to the polyurethane foam backed instrument panels produced by this process.Type: GrantFiled: April 28, 1999Date of Patent: May 22, 2001Inventors: Kristen L. Parks, Charles M. Milliren
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Patent number: 6215060Abstract: In order to ensure long-term reliability when a photovoltaic element is bent or curved to be deformed: (1) In a method for manufacturing a solar cell module having a photovoltaic element encapsulated with a resin on a support member, the step is adopted which forms a bent portion in the photovoltaic element and in the support member, wherein the formation of the bent portion is performed while reducing a working pressure in the normal direction to a surface of the photovoltaic element; and (2) In a solar cell module comprising a photovoltaic element comprising at least one photoactive semiconductor layer on a flexible substrate, at least a part of the flexible substrate is subjected to tensile deformation in the direction parallel to a surface of the substrate with a strain less than a critical strain to lower the fill factor of the photovoltaic element, whereby the photovoltaic element is deformed.Type: GrantFiled: April 20, 1998Date of Patent: April 10, 2001Assignee: Canon Kabushiki KaishaInventors: Ayako Komori, Akiharu Takabayashi, Toshihiko Mimura, Masahiro Mori, Takeshi Takada
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Patent number: 6093460Abstract: A paperboard material 101 is mainly composed of a paperboard having a weight of 200 to 450 g/m.sup.2, a density of 0.65 to 0.82 and a gas permeability of 50 to 200 sec. A first resin layer having liquid-impermeability and thermal resistance is formed entirely on the surface of the paperboard on the inner side of the receptacle, and a second resin layer having permeability to gas and liquid is formed entirely on the back surface of the paperboard. Radial score lines 117 are formed in the portion corresponding to the corners of the paperboard material 101 toward its outer periphery. The score lines 117 do not reach the outer periphery of the paperboard material 101 but terminate at the position at a distance "a" (1 to 3 mm). The score lines 117 are formed by pressing the paperboard with a pressing die from the side constituting the inner side of the receptacle toward the outer side.Type: GrantFiled: February 23, 1998Date of Patent: July 25, 2000Assignee: Toyo Aluminum Foil Products Kabushiki KaishaInventor: Isao Iwaya
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Patent number: 6036804Abstract: A pliable flat disk of laminated construction having a thin top layer of deformable material bonded to a relatively thicker intermediate layer of pliable adhesive sealant material and a removable bottom layer of release paper covering the exposed surface of the sealant material is deformed during installation to cover and seal the head of a fastener protruding from a surface. The disk is installed and deformed by a tool having an end with a recess slightly deeper than the height of the head of the fastener and an interior slightly larger than the outer periphery of the head of the fastener. The release paper is removed to expose the adhesive sealant material and the flat disk is generally centered and stuck, adhesive side down, onto the fastener head.Type: GrantFiled: May 26, 1998Date of Patent: March 14, 2000Inventors: Herbert Rayburn, Susan Rayburn
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Patent number: 5961509Abstract: A flexible absorbent article such as a nappy or a sanitary pad having an absorbent core and a three-dimensional shape. The absorbent article includes a thermoformed layer formed integrally therewith which substantially maintains said three-dimensional shape. The invention also relates to a method for manufacture of the same. The cost of production of three-dimensional absorbent products can thereby be significantly reduced and more complicated shapes can be obtained.Type: GrantFiled: June 18, 1997Date of Patent: October 5, 1999Assignee: SCA Hygiene Products ABInventor: Robert Kling
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Patent number: 5961769Abstract: A separator sheet is formed of a plastic material and has a number of ribs formed on one side thereof. The ribs extend in the direction in which the separator sheet is fed. The sheet is overlaid with a glass mat, and a laminated member obtained thereby is moved into the region between a pair of driving rolls. After being sandwiched by the driving rolls, the laminated member is fed into an envelope apparatus. In an adhesive coating step, a hot melt adhesive is coated on one side of the glass mat. The adhesive is coated at portions C corresponding to the base sections between the ribs of the sheet, in such a manner that the coated adhesive forms a line extending in the longitudinal direction of the glass mat. In a stacking step, the sheet and the glass mat are stacked one upon the other. In the pressing step, the laminated member is sandwiched between the driving rolls, and the adhesive-coated portions of the glass mat are tightly pressed by the ribs provided on the circumferential surface of the driving roll.Type: GrantFiled: May 28, 1997Date of Patent: October 5, 1999Assignee: The Furukawa Battery Co., Ltd.Inventor: Shigenori Moue
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Patent number: 5817265Abstract: 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.Type: GrantFiled: October 3, 1995Date of Patent: October 6, 1998Assignee: Dow-United Technologies Composite Products, Inc.Inventor: Johnny Paul Gendreau
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Patent number: 5795527Abstract: A decorative transfer material includes a base film, a decorative metal vapor deposition layer, a metallic reinforcing layer covering the whole rear face of the metal vapor deposition layer to thereby reinforce the metal vapor deposition layer, a retainer layer for securing the metallic reinforcing layer to the base film, and an adhesive layer for bonding the metallic reinforcing layer to a to-be-decorated object molded by resin. The metallic reinforcing layer is formed of a metallic powder resin layer or a metallic foil layer. After the transfer material is set in dies for injection molding, the dies are closed. Simultaneously with formation of synthetic resin injected into the in-mold dies, the resin is bonded with the metallic reinforcing layer of the transfer material by the adhesive layer. Thereafter, the in-mold dies are opened and the base film of the transfer material is removed, whereby a decorated article is obtained.Type: GrantFiled: April 29, 1994Date of Patent: August 18, 1998Assignees: Nissha Printing Co., Ltd., Pacific Industrial Co., Ltd.Inventors: Yuzuo Nakamura, Masayuki Kyomen, Soichiro Asada, Toshiyuki Matsunami, Hiroyuki Suzuki, Satoru Kawai
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Patent number: 5755908Abstract: A pliable flat disk of laminated construction having a thin top layer of deformable material bonded to a relatively thicker intermediate layer of pliable adhesive sealant material and a removable bottom layer of release paper covering the exposed surface of the sealant material is deformed during installation to cover and seal the head of a fastener protruding from a surface. The disk is installed by a tool having an end adapted to hold the flat disk. The end of the tool has a recess slightly deeper than the height of the head of the fastener and an interior slightly larger than the outer periphery of the head of the fastener. The flat disk is releasably attached on the end of the tool and covers the recess.Type: GrantFiled: February 21, 1996Date of Patent: May 26, 1998Inventors: Herbert Rayburn, Susan Rayburn
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Patent number: 5743979Abstract: 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.Type: GrantFiled: November 13, 1995Date of Patent: April 28, 1998Assignee: Milsco Manufacturing CompanyInventor: James R. Lorbiecki
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Patent number: 5711833Abstract: A process is provided for the manufacture of thin walled ceramic structures, particularly conical or near conical shaped structures. The process involves a tape casting technique wherein a green tape is prepared from a colloidal suspension containing a ceramic powder, a binder system, a plasticizer and a solvent. The suspension is cast into a thin sheet and dried to form a pliable tape. The tape is cut into planar, shaped pieces. Non-planar components of the final structure are preformed from the cut planar tape pieces into predetermined three dimensional shapes. The planar and preformed components are sequentially assembled within a die and compacted under pressure to form a green body. The green body is subjected first, to a burnout cycle to form a brown body, and then sintered to form the unitary, cohesive, thin walled ceramic structure.Type: GrantFiled: July 25, 1995Date of Patent: January 27, 1998Assignee: Thermicedge CorporationInventors: Prasad S. Apte, Ernesto S. Tachauer, Travis Kyle Solomon
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Patent number: 5643384Abstract: 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.Type: GrantFiled: January 10, 1995Date of Patent: July 1, 1997Assignee: Okabe Engineering Kabushiki KaishaInventor: Masaaki Okabe
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Patent number: 5624518Abstract: A housing lining for a piston engine, drive motor, or machine composed of a sound-absorbent layer of fibers. The fibers are compressed and glued to form an essentially pore-free supporting frame at least in the vicinity of the edge of the layer.Type: GrantFiled: June 1, 1995Date of Patent: April 29, 1997Assignee: Firma Carl FreudenbergInventors: Reinhard Stief, Roger Schork, Gerhard Muller-Broll, Thomas Jost, Manfred Mattutat, Klaus-Dieter Schmitt
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Patent number: 5624517Abstract: A foamed plastic basin body for a sanitary basin is provided with a die in which a shell of thermoplastic foil, previously heated to a bonding temperature above the deep-drawing temperature is bonded by a deep-drawing die which serves to shape the shell.Type: GrantFiled: September 13, 1994Date of Patent: April 29, 1997Assignee: Roth Werke GmbHInventors: Willibald Giesen, Michael Schroder, Franz Kind
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Patent number: 5622582Abstract: 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.Type: GrantFiled: May 31, 1995Date of Patent: April 22, 1997Assignee: Viapak Pty LtdInventor: Geoffrey Foxcroft
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Patent number: 5501758Abstract: A reusable and collapsible container having a collapsed configuration for storage and shipment and an assembled configuration for containing a product. The container is formed from a polymeric sheet and has substantially flat panels, hinges connecting adjacent panels, and releasable fasteners on at least some of the panels for holding the panels in an assembled configuration. The sheet has opposing walls separated by longitudinally extending webs. A portion of the hinges cross the longitudinally extending webs and are formed by hot compression of at least one wall of the sheet. Another portion of the hinges are longitudinally extending and are formed by cold compression of at least one wall of the sheet.Type: GrantFiled: December 20, 1993Date of Patent: March 26, 1996Assignee: North America Packaging CorporationInventor: Larry E. Nitardy
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Patent number: 5436046Abstract: An interior finishing web for a motor vehicle or the like comprises three fibrous layers which are put one another, needled together and subjected to a hot-molding to constitute a shaped structure of the web. The three fibrous layers are a first fibrous layer which includes approximately 30 to 90% by weight of polyester fibers and approximately 70 to 10% by weight of polypropylene fibers, a second fibrous layer which includes approximately 10 to 60% by weight of polyester fibers and approximately 90 to 40% by weight of polypropylene fibers and a third fibrous layer which includes approximately 40 to 90% by weight of polyester fibers and approximately 60 to 10% by weight of polypropylene fibers.Type: GrantFiled: May 27, 1994Date of Patent: July 25, 1995Assignee: Ikeda Bussan Co., Ltd.Inventor: Manabu Sakamoto
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Patent number: 5360503Abstract: The semi-finished product according to the invention consists exclusively of liquid crystal thermoplastic polymers (LCP), whereof at least one first liquid crystal thermoplastic polymer (LCP) is in the form of fibers (18) and has a given melting point, and whereof at least one second liquid crystal thermoplastic polymer (LCP) (16) has a melting point below that of the first LCP. This semi-finished product is in particular a fabric. By simply heating under pressure at a temperature equal to the melting point of the second LCP, followed by cooling, a composite material with improved mechanical and physicochemical performance characteristics are obtained.Type: GrantFiled: June 17, 1993Date of Patent: November 1, 1994Assignee: AerospatialeInventor: Rene L. Coffy
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Patent number: 5282306Abstract: The present invention relates to a process for preparing a printed can be draw-forming or draw-redraw-forming a preliminarily printed metal blank or laminate. By forming an original plate for printing by an image processing by a computer, a print image faithful to the original image can be manifested on the side wall portion of the can, and formation of an undesirable stripe pattern can be prevented. Furthermore, a print image excellent in the linearity can be displayed without an error on the draw-formed can in due consideration of the anisotropy owing to the plastic flow of the blank.Type: GrantFiled: April 13, 1990Date of Patent: February 1, 1994Assignee: Toyo Seikan Kaisha, Ltd.Inventors: Imazu Katsuhiro, Akihiko Machii, Masao Ishinabe, Tomomi Kobayashi
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Patent number: 5252160Abstract: A hybrid metal/composite spinner cone used in aircraft applications and a method of manufacturing the same. The spinner cone has a metal outer shell which is bonded during the molding process to an inner structural member of thermoplastic composite. The metal shell imparts several desirable characteristics to the spinner cone such as impact resistance, erosion resistance, appearance, and supplying a lightning strike material to protect the composite structure. The thermoplastic composite has significant property advantages over metal or thermoset systems. The hybrid metal/composite spinner cone is manufactured using a ceramic mold which is less expensive and more readily available than a steel mold. The metal shell provides a barrier between the thermoplastic composite and the ceramic mold and allows the finished spinner cone to be easily released from the mold.Type: GrantFiled: November 15, 1990Date of Patent: October 12, 1993Assignee: Auto Air Composites, Inc.Inventors: John F. Scanlon, Gary Wigell
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Patent number: 5217766Abstract: 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.Type: GrantFiled: June 11, 1992Date of Patent: June 8, 1993Assignee: United Technologies CorporationInventors: Nicholas P. Flonc, Michael W. Brace
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Patent number: 5193265Abstract: A method of producing a cup-shaped sterilizable container from a stretch-drawable composite laminate of a total wall thickness between 30 and 200 .mu.m with an aluminum foil of a thickness less than 40 .mu.m, a sealable plastic inner layer of high extensibility and a plastic outer layer of high extensibility and load-bearing capacity, the side wall of the container running at a side wall angle (a) with respect to the direction perpendicular to the container bottom, is distinguished in that the composite laminate is deep drawn free from folds at a side wall angle of 30.degree. using smooth-walled forming tools then combined deep/stretch drawn and subsequently stretch drawn.Type: GrantFiled: April 17, 1991Date of Patent: March 16, 1993Assignee: Alusuisse-Lonza Services Ltd.Inventors: Olivier Y. Muggli, Andreas Ziegler
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Patent number: 5181409Abstract: In a method of drawing and wall ironing a can body, a blank (1) is cut from a laminate of aluminium or alloy and a polyester film. The blank is lubricated and drawn to a cup (7) having a side wall (8), which is then wall ironed. A terminal margin (14) of the side wall (13) of the wall ironed can is heated to a temperature above 100.degree. C. but below the crystalline melting point of the polyester film in order to prevent delamination of the polyester film from the side wall of the can during subsequent washing of the can. A benefit of the process is that the heating of the side wall margin (14) does not soften the aluminium or aluminium alloy body.Type: GrantFiled: July 22, 1991Date of Patent: January 26, 1993Assignee: CMB Foodcan plcInventors: Peter J. Heyes, Ian M. Leishman, Kevin J. Pope
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Patent number: 5131834Abstract: An isostatic pressurizing bag for consolidating a composite part has an outer flexible elastomer having a fixed resilient outside surface. The outer elastomer surrounds a closed chamber. A thermally expandable inner elastomer is located in the closed chamber. The inner elastomer is selected as an elastomer that can viscously flow or move in response to pressure. The outer elastomer is capable of flexure to relieve expansion of the inner elastomer. The bag is formed by curing plies of uncured silicone rubber around either a silicone gel or a particulated silicone rubber that is capable of phase change to a flowable gel in response to pressure. In use a composite prepreg is overlaid on a surface that defines the shape of a desired part. The isostatic pressurizing bag is located over the prepreg trapping the prepreg between the pressurizing bag and the surface.Type: GrantFiled: December 21, 1990Date of Patent: July 21, 1992Assignee: Northrop CorporationInventor: John E. Potter
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Patent number: 5122213Abstract: 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.Type: GrantFiled: January 15, 1991Date of Patent: June 16, 1992Assignee: Atlantic Research CorporationInventor: Irving E. Figge, Sr.
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Patent number: 5120382Abstract: A method for making a flower pot cover by treating a sheet of material which is non-shape sustaining with a shape-sustaining wax capable of imparting dead fold characteristics and forming the treated sheet of material into a predetermined shape of a flower pot cover.Type: GrantFiled: November 30, 1990Date of Patent: June 9, 1992Assignee: Highland Supply CorporationInventor: Donald E. Weder
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Patent number: 5094706Abstract: A non-metallic unitary baking pan, and especially a baking pan made of plastic, including foam plastic, paper or plastic laminated paper in which a cake or cake-like product can be baked, which baking pan has portions thereof which are thicker and have greater insulating effect than other portions to more uniformly and evenly distribute the heat produced during the baking operation throughout the cake batter or dough being baked. Also disclosed is method for producing such a non-metallic unitary baking pan by means of heated mating dies under pressure the mating dies having portions spaced farther apart than other portions thereof to produce corresponding thicker portions in the pan so formed.Type: GrantFiled: December 20, 1990Date of Patent: March 10, 1992Assignee: The Procter & Gamble CompanyInventor: David J. Howe
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Patent number: 5076874Abstract: A flower pot cover made by placing a sheet of natural or synthetic burlap or combinations thereof, natural or synthetic fiber or combinations thereof, or paper over a material capable of being formed into a predetermined shape by forming a plurality of overlapping folds in said material and then forming at least the two materials simultaneously into the predetermined shape of the flower pot cover.A flower pot cover comprising a sheet of natural or synthetic burlap or combinations thereof, natural or synthetic fiber or combinations thereof, or paper treated with a shape-sustaining agent to retain the predetermined shape of the flower pot cover.Type: GrantFiled: September 15, 1989Date of Patent: December 31, 1991Assignee: Highland Supply CorporationInventor: Donald E. Weder
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Patent number: 5057176Abstract: An automotive headliner comprised of a laminate of double corrugated paperboard. Perforations in all the sheets of the laminate except the back paperboard sheet improve the acoustical performance of the liner. A vapor barrier on the back sheet prevents entry of moisture into the laminate from the roof, and a layer of sound dampening material on the front face of the laminate improves the sound absorption of the laminate. The front corrugation is larger than the back corrugation. When molding the laminate it is first moisturized, then heat molded. Heat is applied until the laminate has regained its rigidity.Type: GrantFiled: October 10, 1989Date of Patent: October 15, 1991Assignee: Manville CorporationInventor: William Bainbridge
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Patent number: 5049426Abstract: A take-up liner for uncured rubber members is a band-like laminate of inextensible reinforcing cloth, flexible foamed layer arranged thereon, extensible cloth arranged thereon and sheet-like elastomer layer adhered thereto and has a helical formed shape.Type: GrantFiled: August 4, 1989Date of Patent: September 17, 1991Assignees: Pyramid Corporation, Bridgestone CorporationInventors: Iwao Kimura, Akira Toyonaga, Koichi Sanada, Koji Nonaka, Kenichi Haraga
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Patent number: 5039364Abstract: A method is described for achieving selective generation of thermal energy from a thin metal film upon exposure to microwave energy. A deactivating material is first applied to a substrate from the thin metal film in a pattern corresponding to the region from which heat is not to be generated. The metal then is applied over the substrate and the pattern in a thickness which normally generates thermal energy upon exposure to microwave energy. Such thermal energy is produced only from those regions where the metal is adhered directly to the substrate.Type: GrantFiled: November 28, 1989Date of Patent: August 13, 1991Assignee: Beckett Industries Inc.Inventors: D. Gregory Beckett, Robert Watts
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Patent number: 4983244Abstract: Graphite blocks are produced by a process wherein one or plural polymer films having a thickness of from 1 to 400 .mu.m and selected from aromatic polyimides, aromatic polyamides and polyoxadiazoles are heat treated to obtain carbonaceous films. A plurality of the carbonaceous films are hot pressure under certain conditions to obtain thick graphite blocks. The blocks have a remarkably improved rocking characteristic and are useful as radiation optical elements such as X-ray or neutron ray monochromators or filters. The blocks may be curved to obtain bent-type graphite articles.Type: GrantFiled: September 19, 1989Date of Patent: January 8, 1991Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Mutsuaki Murakami, Susumu Yoshimura, Naomi Nishiki, Katsuyuki Nakamura, Kazuhiro Watanabe
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Patent number: 4978056Abstract: In a system of packaging of foodstuffs in containers of rectangular horizontal section, each open-topped container is sterilized, filled, and closed with a sterilized closure. The closure is of a laminate including a thermoplastics layer of sufficient thickness to fill an internal discontinuity of the container mouth during heat-sealing of the closure to the container. In making the closure, a portion of laminate is partially severed to form a flap and the laminate is clamped around the flap and drawn to form a shallow dish, to the inside of the base of which is heat-sealed a diaphragm including a pull tab. The thermoplastics layer is on a reflective metal layer and incorporates infrared-absorbing particles and infrared-reflective particles.Type: GrantFiled: November 23, 1988Date of Patent: December 18, 1990Inventors: Martin F. Ball, Ian M. Vokins
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Patent number: 4957805Abstract: Laminated reinforced thermoplastic sheets are made by preparing first and second porous sheets, each having 20% to 60% by weight of reinforcing fibers having a high modulus of elasticity and 40% to 80% by weight of a thermoplastic material differing from the thermoplastic material in the other sheet and applying heat and pressure to cause the sheets to consolidate and adhere together to form the laminate.Type: GrantFiled: July 11, 1988Date of Patent: September 18, 1990Assignee: The Wiggins Teape Group LimitedInventors: Ian S. Biggs, Bronislaw Radvan
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Patent number: 4952264Abstract: A process for producing plastic parts, in particular molded plastic articles that are deep-drawn in a shaping contrivance into molded articles from at least one heated plastic foil, with the molded articles then being separated from the molded article assemblage in the separating contrivance and conveyed with the aid of a transport contrivance to successive processing stations such as a printing unit, or a stacking contrivance or the like. The shaping and detaching of the individual molded articles made of the still warm foil are executed directly after one another at one station, with forming taking place first and detaching then following by means of strip steel cutting, while the form still remains in the closed condition. It is also possible, with the aid of this process, to produce molded articles consisting of two superimposed foils with layers of an absorbent material disposed therebetween.Type: GrantFiled: March 28, 1988Date of Patent: August 28, 1990Assignee: VTM-Verfahrenstechnik AGInventor: Michael Knape
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Patent number: H1162Abstract: Disclosed are a molded composite article having a curved surface which is composed of at least one laminate comprising continuous filaments unidirectionally paralleled and an extensible resinous film, and a process for producing the same. According to the present invention, the laminate comprising the continuous filaments and the film can be easily molded into the article with a curved surface without breakage or a reduction of strength, and the molded composite article is sufficient in strength, and excellent in smoothness of the surface and in appearance.Type: GrantFiled: April 15, 1991Date of Patent: April 6, 1993Inventors: Michio Yamamoto, Haruo Negishi