Abstract: Described are smooth, glossy finished fiber reinforced thermoplastic prepreg materials composed of reinforcement fibers impregnated with and surrounded by thermoplastic. Prior to consolidation, the material preferably consists of thermoplastic fibers and reinforcing fibers, intimately blended together. When heated, with the aid of pressure, the thermoplastic fibers melt, surround and impregnate the reinforcing fibers and provide a smooth, glossy finish to the reinforced article. Excellent surface appearance and the ability to accommodate high-speed processing characterize the prepreg materials of this invention.

Abstract: Fiber reinforced thermoplastic molded products, sheets, and the like, having a glossy surface are produced by intimately blending discrete reinforcing fibers (e.g. fiberglass) and thermoplastic fibers (e.g. polypropylene or polycarbonate) into a web. The web is heated to the melting point of the thermoplastic fibers while applying pressure, to eliminate air and press the web into a consolidated structure. Breakage of the reinforcing fibers is minimized by limiting the thickness of the web and limiting the pressure so as to produce a consolidated structure with minimal fiber breakage and a Notched Izod of at least one. Layering consolidated structures, some without reinforcing fibers, may be heated and pressed together to form a final structure having a thickness greater than the individual structures. The great majority of the fibers are provided so that the fibers of each type are within the range of about 0.5-5 inches.

Abstract: In order to make a synthetic membrane for a gas meter of the measuring chamber type, an initial structure of polyester fibers, which are preferably woven, is placed between two films of hot meltable elastomer (polyurethane). The hot meltable material is raised to its softening temperature and pressure is applied to cause the films to adhere to the woven structure.

Abstract: A method of making a laminated structure in which a polyethylene element is bonded directly to a metal substrate by the application of heat and pressure is characterised by the selection of the polyethylene, for the purpose of obtaining good adhesion, to be a linear low density polyethylene having a density from 0.91 to 0.94 g/ml.sup.-1 and a melt flow index in the range 0.2 to 2.0 g/10 min, produced by low pressure co-polymerisation of ethylene and but-1-ene. The polyethylene may be pre-treated, e.g. by corona discharge, glow discharge or flame treatment to further improve the adhesion. The polyethylene element may be a film applied to one or both sides of the metal substrate which may be a sheet or foil.

Abstract: A casing for magnetic recording medium has a laminated structure in which a printed plastic film is bonded on one surface of a raw plastic sheet.

Abstract: An ovenable food tray for cooking foodstuffs, such as frozen foodstuffs, in an oven of either the microwave or conventional type. The tray is formed from a flat, unitary laminate blank by deforming the blank in any conventional male and female die apparatus under pressure and heat. The laminate includes a food contacting PET bi-axially oriented film coating adhered to a paperboard base stock by means of a crosslinkable adhesive. The use of such a coating and such an adhesive formulation permits use of the tray in oven temperatures to about 400 degrees F. without delamination of the coating from the paperboard or cracking of the coating.

Abstract: Disclosed are interleafed fiber-reinforced thermoplastic composites formed by introducing a ductile interleaf block copolymer layer to a fiber-reinforced thermoplastic layer. Also disclosed are methods for producing such composites. These composites are useful in numerous applications where toughness, impact strength and resistance to delamination are desirable.

Abstract: A method of manufacturing a decorative automobile roof cap by forming a flat composite of a thermoplastic cover member laminated to a core layer foam sheet, thermoforming the composite to the desired shape and forming the edges of the roof cap by removing a portion of the core layer from the cover member and then wrapping the excess cover member around the edges of the core layer and securing it to the underside of the core layer to form an edge covered with the cover member.

Abstract: The invention provides a filtration face mask which has an expanded filtration surface area and high filter efficiency. The mask includes at least two sidewall portions generally extending away from the face of the wearer and away from an annular base. A frontal portion bridges the sidewall portions and at least two supporting arche structures are disposed at the junction of the sidewall and frontal portions.

Abstract: A process for preparing a two-ply foam molded article, characterized by heating a foamable polyolefin sheet which is in its not yet foamed state to form a foamed polyolefin layer, integrally laminating a fabric on one side of the resulting foamed polyolefin layer which is still in a melted and softened state to form a laminate and simultaneously draw-forming the resulting laminate to shape the two-ply foam molded article.

Abstract: A high pressure laminate comprising a plurality of heat molded sheets impregnated with duromeric synthetic resins characterized in that several of these sheets form on at least one surface of the laminate a heat-shapable surface layer (2,3) while the remaining sheets form a non-heat-shapable region which includes a core layer of the laminate.

Abstract: The invention relates to a method for the automated manufacture of laminated plastics products, in which a pack of superimposed layers of thermosetting material, for example, sheets of resin-impregnated paper, is first formed, and the pack is placed on a rigid support structure for supporting the pack and keeping it in the correct position; the rigid structure and the corresponding pack are supplied by gripping and transfer means to a moulding press which provides for hot-forming of the above pack and, when moulding is completed, the rigid structure and the respective thermoset plastics laminate are separated and directed to respective unloading stations.

Abstract: A thermally insulating covering is provided incorporating a synthetic resin-impregnated carrier mat of fibers and an aluminum foil layer on that entire side of said carrier mat which is to face a heat source. A layer of insulating material is preferably located in predetermined areas between the carrier mat and the aluminum foil. A process for producing such covering is also provided.

Abstract: A method for the manufacture of a laminated element comprising a thermoformed cellular core material and one or more reinforcing and/or decorative web layers which comprises applying an adhesive coating to said web, placing the thermoformable cellular core material on said coated web to form an intermediate laminated element, and placing the intermediate laminated product without substantial preheating in a heated mould to deform the thermoformable cellular core material to a desired final shape and to cure the adhesive.

Abstract: Disposable diapers having elasticized waistbands which are shaped to conform to the wearers' waists and method of making them. The shaped disposable diapers are made by affixing an elastomeric material having a heat unstable state and a heat stable and elastic state to the diaper while the elastomeric material is in its heat unstable state and then heating the elastomeric material while the diaper is restrained in a folded configuration.

Abstract: A method of making a ballistic helmet and a helmet made by the method in which each of the plies making up the body is formed from a hexagonal blank cut from ballistic cloth and provided with slits extending from the apices thereof toward the center to form a central area and segments extending from the central area. As the blanks are laid up in a mold cavity the segments overlap to provide first portions which overlap and second portions which do not. As successive blanks are laid up they are rotated slightly to stagger the portions of adjacent plies. As the laying up operation proceeds, progressively smaller blanks are laid up between adjacent relatively larger blanks.

Abstract: This invention encompasses a process for making multilayer containers by conventional roll fed sheet method, with minimal scrap loss, which comprises the steps of preparing a monolayer sheet of a first thermoplastic material by conventional roll fed sheet methods, cutting or punching billets from a second thermoplastic material sheet, heating the monolayer sheet and the billets to a temperature where both the sheet and the billets become tacky, placing the billets at a position on the sheet so that the billets are in a position over forming cavities in a forming mold at the time of forming, while maintaining the billets and sheet at a temperature where the sheet and billets are tacky and weld together, and forming containers from the welded billets and sheet so that the web scrap left after forming is pure monolayer sheet.

Abstract: The method of this invention is particularly suitable for forming a permanently deep drawn contour in a laminate, such as a self-supporting polymer backed carpet laminate utilized by the automotive industry. The method includes forming a generally planar laminate wherein the carpet or cloth finish sheet is spaced from the sides of the polymer sheet, releasably clamping the polymer backing sheet to the side members of a frame assembly including a portion which is hingedly attached to the side members adjacent the area where the deepest draw is to be formed in the laminate. The laminate is then heated in the frame assembly and formed in a die press having at least one die member which is received in forming contact with the laminate between the side members.

Abstract: A vacuum molding process for adhering a porous, foam-backed fabric 50 to a thermoplastic substrate 60 and for providing a nonplanar contour to the substrate 60 with fabric 50 adhered thereto. The porous, foam-backed fabric 50 is loosely positioned over a female mold 30. The substrate 60 is heated sufficiently for the substrate 60 to sag. The sagging substrate 60 is deposited over the female mold 30 in a manner whereby the substrate 60 contacts the fabric 50 around an effective mold perimeter 36. A vacuum applied through the female mold 30 is transmitted through the porous foam-backed fabric 50 and attracts the sagging substrate 60 into the mold 30. The attraction causes contact and adhesion of the heated substrate 60 and the foam-backed fabric 50.

Abstract: Non-slip properties are imparted to molded plastic articles by adhering a layer of latex or a latex-impregnated sheet material onto the surface of the molded article. Preferably, the latex layer is applied prior to thermoset curing of the molded article and is adhered to the thermoset article during the curing process. The plastic may be reinforced, and the latex is preferably an acrylic latex impregnated into a sheet material such as cloth or paper.

Abstract: An article for protecting a substrate includes a preshaped member having a shape similar to that of the substrate being protected, the article having a thin layer of gel disposed in intimate contact with an inner surface of the member such that the gel is disposed in intimate contact with the substrate when the member is disposed therearound. Preferably, the gel comprises an open looped three-dimensional network, the gel being relatively soft, elastic, and having an ultimate elongation in excess of 100%.

Abstract: The present invention contemplates a method of manufacturing a laminated sheet having a non-skid surface. In a preferred embodiment a method of manufacturing a decorated unitary laminated tray having a thermoplastic non-skid layer is disclosed.

Abstract: A process for making moldings with areas of marked final deformation from highly sensitive materials, such as tangled-fiber fleeces, in which the flat material is molded in the softened state between press molds. Prior to the actual molding process and independent of the desired molding of the final molding in a particular area and without any precompression of the material, the material is mechanically drawn between the corresponding press molds to such an extent that the resulting material flow roughly corresponds to the feed requirement for the final molding operation. The necessary auxiliary device comprises one or more push-rods with ram heads, which can be brought between the press molds when the press is in the open position and can be moved in the desired directions in the manner of an automated human fist.

Abstract: A method for preparing stampable composites of polymer of olefin and fiber mat composites which are a mixture of glass fiber and carbon fiber by surrounding a fiber mat of a mixture of glass fiber and carbon fiber with a matrix of polymer of olefin. A stampable composite of polymer of olefin and fiber mat produced by such a method.

Abstract: The present invention relates to a glue-free method for sealing closures to paperboard food containers, and also to the novel closures for such method. The present invention is particularly applicable to containers for moisture sensitive food items such as salt, and is characterized in the use of a thermoplastic vinyl chloride ethylene copolymer which functions both to provide a heat seal and effective resistance to moisture vapor transmission. The copolymer has sufficient slip to permit handling of the closures in automatic forming and heat sealing equipment.

Abstract: A method of producing a unitary curved structure having a honeycomb core by coating a mold with gel, applying a layer of reinforced fiberglass plastic to the gel to receive, after partial curing, a light layer of chopped glass fibers (about 3/4 ounces/sq. ft.) and a mixture of catalyzed resin and chopped fiber strand. The resulting surface may be rolled to remove bubbles and oversprayed with catalyzed resin. A Raw Kraft paper honeycomb is placed into the wet laminate and completely covered with wax paper weighted with sand bags to approximately 10 pounds per square foot to press the honeycomb into place and seal same. The resin is absorbed in and climbs the honeycomb walls, and heat and styrene gas are liberated into the cells. The bags and wax paper are removed after partial cure, excess styrene fumes are blown away, and the honeycomb is lightly oversprayed with a catalyzed resin.

Abstract: A process of making a container of the dishtype, including, on the one hand, a bottom 40, walls 31 to 34 and 41 to 44 and edges 30a to 30d of exterior cardboard and, on the other hand, of a thermo-formed layer 2 of synthetic material. The edges 30a to 30d are constituted by the sides of a frame 30 and are in one piece. The frame 30 is integral with the walls 31 to 34, bent downward. The bottom 40 is integral with the walls 41 to 44, bent upward and complimentary to the walls 31 to 34. All walls are placed so as to be on the same level and are maintained by the layer 2.

Abstract: A structural article such as an automobile bumper includes a plastic body portion having an outer surface and a single metal sheet stretched to be completely disposed about and fixedly secured to the outer surface. The body portion provides a structural member and the metal sheet provides a continuous metal trim thereon.A method of forming the structural article includes the steps of compressing a sheet of metal and a sheet of heated softened plastic material within a mold so as to simultaneously cool the plastic material during the compression to set the molded plastic and stretch the metal about the outer surface of the molded plastic.An apparatus for forming the structural article includes a female mold portion including a clamping frame disposed about the periphery thereof. The clamping frame includes toggle clamps for clamping the peripheral edges of the sheet of metal to the periphery of the female portion.

Abstract: A composite useful as a ski sole comprising polyethylene particles in a polyethylene film, the former having a greater hardness or higher melt index than the latter, which is capable of renewably forming fibrils extending from a surface thereof under the abrasion characteristic of skiing conditions. The particles may have been treated with a material which is incompatible with or reduces the adhesion to the film-forming polyethylene.

Abstract: Apparatus is provided for preforming automobile rooftop coverings made of flexible sheets of vinyl and the like. The flexible material is treated with a thermosetting composition and then applied to an automobile rooftop form. Pneumatic tensioning means are attached to the edges of the material at a plurality of spaced-apart points to tension it over the form to a predetermined orientation and shape while maintaining the forces on the material substantially in equilibrium. The material is heated to set the thermosetting composition. Clamping means lightly engage the material to hold it in the predetermined shape until the setting temperature is reached and then firmly engage it to form maginal flanges thereon. The shaped material is then removed from the form by a vacuum carrier and then cooled and trimmed in the carrier.A pressure-sensitive adhesive and release liner may also be applied to the material so that after it is shaped it can be directly adhesively secured to an automobile rooftop.

Abstract: A wheel rim is formed by separately forming rim halves of fiber sheets arrayed in different directions so that the fibers are isotropic around the circumference of the rim, and by welding the halves together with a ring formed of carbon fibers.

Abstract: Lightweight aircraft transparencies are shaped to a desired configuration by laying up a plurality of flat oversized plastic sheets in a desired sequence to form a flat assembly. Portions of the marginal edges of the flat assembly are supported on a female support ring having a non-planar supporting surface. The assembly is first shaped at a temperature below its deformation temperature to a preliminary shape where its marginal edge portions conform to the non-planar supporting surface of the female support ring. While the marginal edges of the preliminarily shaped assembly are maintained in conformity with the female support ring, the assembly is uniformly exposed in an enclosed autoclave to elevated pressures to minimize outgassing and to elevated temperatures above its deformation temperature. A male form having an outline smaller than the female support ring engages the central portion of the preliminarily shaped assembly to impress the desired final shape thereto, e.g., a compound configuration.

Abstract: The invention relates to a process for continuously manufacturing a composite band comprising a plastic sheet bonded to an aluminized pellicle, these two components consisting of separate bands before carrying out the process. The composite band made by the process can be used for instance for insulating or padding. This band can also be used after cutting and thermoforming as a pan or container for perishable products such as meat. The perishable product is put in the pan, and both are covered with a plastic film to give a stocking and hygienic presentation. To carry out the process and to bond the basic plastic band (expanded polystyrene) to the aluminized pellicle, these two sheets are introduced between calendering cylinders with interposing between the two sheets an intermediate film of plastic material at softening temperature to provide the adhesion. Of course, it is the non-aluminized side of the pellicle which is in contact with the polystyrene basic band.

Abstract: A one step method of applying a sealant onto the inside surface of a pipe, such as a gas pipe, to repair any defective portions that are likely to cause a leak and should be repaired. The sealant is applied and it is then dried and solidified to seal the leak portions of the pipe. Preferably, an injection means is used for supplying the sealant in a cylindrical shape so that every portion of the inner surface of the pipe will be coated.

Abstract: This invention relates to a method of producing interior material of corrugated cardboard used for a ceiling of a car, for example.Corrugated cardboard base material is plasticized by being heated and moistened while in a flat plane. Thereafter, the corrugated cardboard base material thus plasticized is pressed in a forming die having a low temperature such as a room temperature to be shaped in a predetermined manner. Afterward a covering sheet is disposed thereon having a thermally melting sheet provided thereon so as to be faced toward the corrugated cardboard base material thus shaped, they are pressed in the forming die to melt the thermally melting sheet by the preheated shaped corrugated cardboard base material to bond the covering sheet to the corrugated cardboard base material so as to produce interior material.

Abstract: A release film is coated with a thin layer of metal by, for example, a vapor deposition process. The film is then stretched over a composite object, made, e.g., of fiberglass-epoxy or graphite-epoxy, which one desires to metallize. A treatment involving either vacuum or pressure and that may involve heat is used to transfer the thin metal layer to the composite object. The stretchable film is then peeled off the object, leaving a metal coating bonded to the object. The epoxy resin or other adhesive in the composite material gives structural integrity to the object as well as provides a bond for the metal, so that the composite object may be molded and metallized in one step. Alternatively, a two-step process of molding then metallizing or metallizing then molding can be employed.

Abstract: A method and apparatus for sealing plastic or synthetic coated sealing surfaces of cardboard containers to each other is disclosed. One feature of the invention resides in preheating (by 15) of at least one (48) of the plastic or synthetic layers and then sealing (station 16) by the simultaneous application of heat and pressure. Another feature of the invention resides in the fact that the pressure is applied at spaced intervals (by 40) and in such a manner that one (47) of the plastic or synthetic sealing layers remains with the top of the box upon removal thereof. A container sealed in such a manner is also taught.

Abstract: A container closure which is thermoformed from a sheet of two different materials which are bonded together, the material forming the inside of the closure being relatively soft to serve as a liner.

Abstract: A method of producing a molded leather holster capable of holding the holstered item in the holster by friction or pressure due to the molding and which is capable of retaining its molded shape in the presence of moisture, the method comprising preparing a laminate of at least one layer of leather and a layer of a heat moldable thermoplastic material, heating the laminate to the molding temperature of said thermoplastic material, inserting a forming core inside said holster and applying pressure from the outside of said holster while said temperature is reduced to a level below the molding temperature.

Abstract: A flexible radiant energy reflecting surface, including a laminate composed of a metal ply, a glass ply having a front face and a rear face, the glass ply being bonded over its entire rear face to the metal ply, in an inter-ply bond, and a radiant-energy reflecting surface associated with one of the plies. The relative thicknesses of the glass and metal plies, the moduli of elasticity of the glass and metal plies, and the efficiency of the inter-ply bond are such that the rear face of the glass ply is not subjected to tensile stresses when the laminate is flexed, within the elastic limit of the metal, such that the front face of the glass ply has a concave curvature of a radius of 10 meters.

Abstract: Disposable contraceptive intravaginal cervical barriers of one, two, three, four, or five layers in the form of standard pessaries with at least one layer impervious to the passage of sperm, with a medicament such as spermicide, germicide, or an abortion inducing agent either impregnated into a foam plastic layer or in the form of a layer of gel or powder, said medicament being activatable upon contact with an aqueous solution.Methods of producing disposable contraceptive barriers either as a wet foam plastic method wherein medicament is added to liquid foam and the resulting mixture is formed in a mold with any subsequent layers then added, or as a dry foam plastic method wherein layers including a layer of medicament in the form of a gel or a powder are superposed in sequence and formed in a die.

Abstract: A seamless expandable bag filter of nonwoven material using conventional filtering media and having 62% greater extended area than other commercially available extended arm filters and incorporating broad, flat sealing collars or plates on each side of the neck of the bag and sealing them together to insure a no-leak installation.

Abstract: A method of deep drawing of foam material mold parts made of flat foamed plates, by which the plate which is clamped in a frame is heated on both sides and is sucked against the upper side of a core piece which moves into the plane of the frame, the upper side corresponding to the profile of the mold. The suction takes place with an intermediate placement of a foil, the latter being adhesive material--repelling at least on its interior side. The foil is fastened to the foam material plate by means of a self-adhesive layer.

Abstract: This invention relates in general to the manufacture of segmented mirror solar collector troughs and specifically to the method and apparatus employed to initially subject the faceted segments to a lateral compression by the application of a vacuum prior to impregnating the segments in a fiberglass substrate which maintains the compressive force when the vacuum is removed.

Abstract: In a method of press-forming a planer board of corrugated paperboard into a curved board which serves as the substrate of, for example, an automobile roof trim board by utilizing a thermoplastic adhesive in the production of the corrugated paperboard and applying heat to the planer board through dies in a hot-press, the liners of the corrugated paperboard are prevented from wrinkling by preheating the planer board so as to soften the thermoplastic adhesive therein immediately before placement between the dies. An apparatus to perform this method comprises a board carrier which has heaters and can carry the planer board into the hot-press with continued heating of the board.

Abstract: The method includes the following steps: (1) a microsheet of glass is drawn from a glass melt; (2) a reflective layer, such as silver, is deposited on one surface of the microsheet; (3) a first flexible backing layer, such as fiberglass, is bonded to the reflective layer; (4) the combination of the microsheet with the reflective layer and the first backing layer is formed over a mandrel which is preferably in the form of a parabolic cylinder; and (5) a honeycombed layer, with a second fiberglass backing layer, is then bonded to the first backing layer. The product produced by the steps 1-5 is then cured so that it retains the desired configuration; i.e. parabolic-cylindrical, after it is removed from the mandrel.

Abstract: Thermoforming, utilized for making articles from sheets of thermoplastic ins, does not always yield articles having desired strength properties. It has been suggested that both thermoplastic and thermosetting layers be used to making the articles stronger. However it was virtually impossible to bond the layers together. A process is provided herein for obtaining that bond.

Abstract: Thermoforming, utilized for making articles from sheets of thermoplastic ins, does not readily yield articles having desired strength properties. Using both thermoplastic and thermosetting resins in the process results in articles embodying fabrication stresses akin to those in prestressed concrete.

Abstract: A plane plate of corrugated paperboard, which is produced by bonding a corrugated medium and at least one liner board with a thermoplastic resin, is shaped into a curved plate by means of a hot-press so that the resin fluidifies and allows the medium and each liner board to make individual and slipping movements during press-forming. The resin hardens upon subsequent temperature reduction and affords the curved heat and sound insulator plate a good shape retentivity. This is a continuation of application Ser. No. 686,314 filed May 14, 1976, now U.S. Pat. No. 4,093,482.

Abstract: A coated paperboard product and a process for producing the same which includes corona discharge treatment of a paperboard surface and subsequent extrusion of molten polyester thereon. The resulting product has a very high degree of adhesion between the paperboard and polyester layers, and is capable of being utilized for forming pressed food trays which can be subjected to oven cooking temperatures.