Abstract: Method of creating a copied fine structure, which produces a diffractive optical effect onto the target surface, includes: using a transfer foil manufactured from thermoplastic, on the surface of which is first created an original fine structure, which produces a diffractive optical effect; placing the transfer foil on the target surface such that the original fine structure is in contact with the target surface; heating the transfer foil to a temperature, which is close to the glass transition temperature of the material of the transfer foil; Simultaneously during the heating or immediately after the heating lightly pressing the transfer foil against the target surface, whereby material from the transfer foil adheres to the target surface; and removing the transfer foil from the target surface, whereby the adhered material makes up a copied fine structure, which is a mirror image of the original fine structure of the transfer foil.

Abstract: An external covering and method of making an external covering for hiding the internal endoskeleton of a mechanical (e.g., prosthetic) device that exhibits skin-like qualities is provided. The external covering generally comprises an internal bulk layer in contact with the endoskeleton of the prosthetic device and an external skin layer disposed about the internal bulk layer. The external skin layer is comprised of a polymer composite with carbon nanotubes embedded therein. The outer surface of the skin layer has multiple cone-shaped projections that provide the external skin layer with superhydrophobicity. The carbon nanotubes are preferably vertically aligned between the inner surface and outer surface of the external skin layer in order to provide the skin layer with the ability to transmit heat. Superhydrophobic powders may optionally be used as part of the polymer composite or applied as a coating to the surface of the skin layer to enhance superhydrophobicity.

Abstract: In a method for connecting two objects, comprising applying to at least one of said objects a volume of an adhesive of the type which, when cured, is flexible and thereafter a step of bringing the other of said objects in contact with said volume of adhesive, there is the additional step of, before applying said volume of adhesive, providing a stiffening device extending from and attached to the object to which said volume is to be applied and with a height which is less than the height of the completed volume of adhesive, after which additional step the volume of adhesive is applied around said stiffening device.

Abstract: A sealing device and method of making it for insulating and sealing a joint electrically connecting a wire or ribbon anode to an electrical cable. The cable is insulated except at an open region where the wire anode is connected to it. The sealing device comprises a body of an insulating material molded in situ about the electrical joint to completely cover it and bond to portions of the electrically insulating covering contiguous with the joint to thereby insulate the joint and prevent the ingress of water or other materials into the joint.

Abstract: A method of manufacturing an orthodontic appliance may include molding a plurality of green bodies in plurality of molds and coupling the green bodies so as to form an intermediate green body. The orthodontic appliance may be an orthodontic bracket body. The plurality of green bodies may be molded so as to be devoid of any undercut formations. Coupling the plurality of green bodies may form the intermediate green body to include at least one undercut formation. An orthodontic bracket may include an undercut formation not capable of being formed in a single shot molding process and not formed through post-formation processes. The undercut formation may include a guiding track and/or a retaining recess configured to receive a portion of the ligating member. The ligating member may include a flexible ligating portion that overlies the archwire slot and a relatively rigid main body portion.

Abstract: A fuselage structure includes a fuselage body and framework for stiffening the body. The framework includes at least one frame member having a duct therein for routing a utility through the body.

Abstract: The present invention relates to photovoltaic roofing tiles and methods of manufacturing them. One aspect of the present invention is a photovoltaic roofing tile comprising: a polymeric carrier tile having a top surface and a bottom surface; and a photovoltaic element affixed to the polymeric carrier tile, the photovoltaic element having a bottom surface and a top surface having an active area. Another aspect of the invention is a method of making a photovoltaic roofing tile comprising inserting into a compression mold a polymeric tile preform having a top surface and a bottom surface, and a photovoltaic element, a surface of the photovoltaic element being disposed adjacent to a surface of the polymeric tile preform; compression molding the polymeric tile preform and the photovoltaic element together to form an unfinished photovoltaic roofing tile; and finishing the unfinished photovoltaic roofing tile to provide the photovoltaic roofing tile.

Abstract: A production method of synthetic and coated leather in general is disclosed, characterised in that it uses a micronized resin powder preferably with dimensions lower than 120 micron. Moreover, a micronized polyurethane elastomeric polymer powder with dimensions lower than 120 micron is disclosed. Advantageously, the said powder can be used to produce an eventually discontinuous sintered film, in particular for production of imitation leather material.

Abstract: The present invention provides a fuel cell separator with a gasket manufactured by integrally forming a gasket on one side of a separator; independently injection molding a frame gasket on a frame such that a first airtight portion covers the entire surface of the frame to maintain the shape of the frame gasket and a second airtight portion projects upward and downward from both ends of the first airtight portion; and bringing the first airtight portion of the frame gasket into contact with the other side of the separator with the gasket formed on one side thereof. To create a fuel cell stack in certain embodiments, the invention stacks the second airtight portion of the frame gasket on another second airtight portion of an adjacent unit cell with a membrane-electrode assembly interposed therebetween.

Abstract: A rotocast composite hybrid method for efficiently making strong but lightweight parts. The method includes filling a mold with a volume of resin through an access port and then sealing the access port by positioning a lid over the access port. The method includes mounting the mold in a rotocasting machine and then operating the rotocasting machine to rotate the mold about two orthogonal axes until a layer of the resin is applied uniformly over an inner surface of the mold to form an outer wall of a part. The method includes removing the lid and then applying a reinforcement material (e.g., sheets of woven fiberglass) to an inner surface of the outer wall of the part through the access port. The applying of the reinforcement material also involves wet layup such as by binding the reinforcement material to the inner surface by applying additional resin to the reinforcement material.

Abstract: A method of manufacturing a component comprising a hollow axisymmetric body formed of a cured composite material is provided. The method includes the step of positioning the constituents of the composite material in a mould corresponding to at least a portion of the hollow axisymmetric body. The composite material is cured into a composite part, and residual stresses are generated in the composite material during the curing by controlling the temperature of the constituents in the mould. When the composite part is released from the mould, relaxation of the residual stresses causes one or more regions of the composite part to deflect in the radial direction of the hollow axisymmetric body, the position of greatest radial deflection of each region having a radial deflection which is at least 0.1% of the greatest diameter of the hollow axisymmetric body.

Abstract: A batwing beam is produced from an LED package having a primary LED lens by molding the LED lens directly over an LED on a package substrate. The LED lens includes a cavity over a center of the LED. The cavity surface reflects light from the LED through total internal reflection (TIR) or through a reflectivity gel coating. The cavity may be a cone or a pyramid.

Abstract: This invention provides packaging material made from starch and cellulose fiber obtained from recycled paper waste. The process involves drawing a suspension of pulp and starch in water into a mold, and withdrawing water from the suspension while in the mold. Bubble-shaped wrap and bracing made according to the invention are designed for use as cushioning for the shipment of fragile or irregularly shaped items. The packaging is biodegradable when exposed to water in the environment.

Abstract: The present invention is directed to a ball including an outer shell formed from a first thermoplastic material and having an inner surface defining a cavity, outer details formed from a second thermoplastic material and disposed on at least a portion of the outer surface of the outer shell, and a core formed from a foamable polymeric material and disposed within the cavity of the outer shell. The ball may be produced by forming a pair of half shells having inner surfaces defining corresponding portions of the cavity of the outer shell, forming the outer details on the outer surface of at least one of the half shells, and foaming a polymeric material to form the core.

Abstract: A method of manufacturing a portion of a portable electronic device includes forming a glass fiber laminate sheet to provide a formed glass fiber laminate body, and overmolding a rim on the body. The rim includes a connector for coupling with a complementary part of the portable electronic device.

Abstract: A water tank includes a long water storage part and a partition unit including partitions to partition the water storage part into a plurality of storage spaces. Communication holes are formed at the partitions to allow the storage spaces to communicate with each other. Spatial efficiency and a first in first out effect are improved.

Abstract: The invention relates to a multilayer product comprising a first layer (A), a second layer (B), a third layer (C), and a fourth layer (D). The first layer (A) is a scratch-resistant protective layer having a minimum extinction of 0.3 at 340 nm, the second layer (B) is an alkyl acrylate layer having a minimum extinction of 2 at 340 nm, and the third layer (C) and the fourth layer (D) contain a UV-stabilized polycarbonate. The invention also relates to a method for manufacturing the multilayer product.

Abstract: The present disclosure pertains to composite articles, and in particular a composite face plate for a golf club-head, and methods for making the same. In certain embodiments, a composite face plate for a club-head comprises a lay-up of multiple, composite prepreg plies. The face plate can be made by first forming an oversized lay-up of multiple prepreg plies having a central portion and a sacrificial portion surrounding the central portion. The lay-up is at least partially cured in a mold under elevated pressure and heat. The lay-up is then removed from the mold and the sacrificial portion is removed from the central portion to form a composite part that is substantially free of defects.

Abstract: A hybrid data disc, method and system of forming the disc are disclosed. The hybrid disc includes a first substrate structure bonded to a second substrate structure, and at least two data layers of different formats for access from different sides of the disc. One example provides the second substrate structure with a second substrate that has at least one curable material layer on each side of the second substrate, and the curable material has a property that results in shrinkage associated with curing of the material. Other examples provide a data disc with different stacking ring configurations, a thinner substrate and substrate structures of opposite curvature.

Abstract: VOC or compressed gas containment devices, such as polymer fuel tanks, are made from a polyoxymethylene polymer composition. The polymer composition contains a polyoxymethylene polymer that is directly or indirectly chemically attached to an impact modifier. In one embodiment, for instance, a coupling agent bonds the impact modifier to the polyoxymethylene polymer. In order to preserve the permeability of the polymer material when combined with the impact modifier, a polyoxymethylene polymer is used that contains a low level of low molecular weight constituents.

Abstract: A ballistic panel provides protection from various munitions. The ballistic panel may be configured to conform to various contours and shapes. In this way, the ballistic panel may be used to create or replace traditional non-ballistic panels, such as those found in structures, vehicles, and device enclosures. The ballistic panel may comprise one or more layers of material including fiberglass, metal, mesh, ceramic, and natural and synthetic materials, among others. The ballistic panel may protect individuals, property, devices, and other assets from physical damage, electromagnetic radiation, and the like. The ballistic panel may be inexpensively constructed with low cost materials and manufacturing processes.

Abstract: A manufacturing apparatus of a fiber-reinforced resin strand including spreaders that spread a reinforcing fiber bundle and are provided inside a crosshead to which a molten resin material is supplied continuously from an extruding machine, twisting rollers provided at a downstream position from an exit nozzle of the crosshead and that pultrude a fiber-reinforced resin strand formed of a resin-impregnated fiber bundle from the exit nozzle while imparting twists thereto, and twist retaining rollers provided at a downstream position from the twisting rollers and that retain twists of the fiber-reinforced resin strand. The twisting rollers and the twist retaining rollers are made of metal with asperities being formed on the surface thereof. The manufacturing apparatus can achieve excellent durability and is capable of manufacturing a fiber-reinforced resin strand at a high production rate without causing slipping.

Abstract: A method for manufacturing a face component of a golf club head from slit plies of unidirectional pre-preg material is disclosed herein. The slitting is preferably diagonally along the unidirectional pre-preg material. The slit plies are placed in a mold in an alternating manner and the plies are compressed to form the face component. The slitting allows the pre-preg material to move within the mold during the compressing step.

Abstract: A mandrel having an out-of-plane curvature and a corresponding in-plane change in mandrel geometry is used to fabricate substantially wrinkle-free, fiber reinforced stiffeners having an out-of-plane curvature.

Abstract: A multi-surface appliquing method is provided for a melamine container. The method is process for producing a melamine container that has inner and outer appliques performed with a single mold in a single processing machine. A single mold used in a single processing machine is used to mold a blank formed of a material and the blank provides an adhesion force before being completely cured. The adhesion force is used, together with glitter powders (resin based glitter powders of melamine) adjusted for a different curing time, in such a way that the properties of the two materials, together with producing condition realized through adjusting a hydraulically operated processing machine, allow for production of a melamine container having inner and outer surfaces of applique with a single set of mold.

Abstract: The present invention generally provides mold modules for constructing boat hulls, methods of constructing boat hulls using the mold modules, and hulls constructed using the mold modules. The modules may be adjustable, and may be included in a kit for building the hull of many boats of different dimensions but generally the same shape. Each mold module generally comprises a mold in a shape complementary to that of a portion of a boat hull, and an edge mold to form the edge of the hull part formed by that mold module. A mold module according to the present invention may also comprise one or more mold adjustment areas, and calibrators for selecting the boat hull dimensions. Methods for using the aforementioned mold modules generally comprise steps of molding hull parts, removing them from the mold modules, aligning them and finally attaching them together.

Abstract: A toy for a pet and method for fabricating a toy for a pet having a shaggy thick fleece fabric outer coating and an inner body of an elastically deformable rubber core with the rubber hollow core body molded from at least two rubber core sections to form a rubber seam between the sections, and with the sheep fleece covering formed by adhesively attaching the pieces of thick fleece fabric to the rubber core body with each piece of fabric being of an appropriate size and in a thickness of between about 8 mm to 20 mm and having cut edges for forming the outline of a predetermine pattern corresponding to the desired shape for the pet toy and in an arrangement with the cut edges abetting each other on the rubber core surface so that the entire peripheral surface of the rubber core body is covered and with one or more fabric seams being formed which lie along the mated edges in a pattern having an orientation independent of the orientation of the rubber seams.

Abstract: A body-of-revolution composite structure is fabricated by providing an OML mold having an interior tool surface on which a composite layup may be formed and moving a manipulator through the interior of the mold. An end-effector on the manipulator is used to apply composite material to the tool surface, and is moved circumferentially over the tool surface.

Abstract: Disclosed is a method for manufacturing a fiber-reinforced composite sabot for use in APFSDS (Armor. Piercing Fin Stabilized Discarding Sabot) wherein a plurality of fiber mats are laminated instead of one-directional prepreg ply and whole part is reinforced by stitching through long fiber bundle in order to enhance circumferential shear strength, and high quality fiber-reinforced composite sabot is manufactured in a short time using resin-injection vacuum assisted resin transfer molding after stitching.

Abstract: A polyurethane foam for vehicles is obtained by reaction, foaming, and curing of a polyurethane-foam raw material comprising polyol, polyisocyanate, a blowing agent, and a catalyst, and is used for vehicle parts. The foam raw material comprises expanded graphite and an inorganic compound hydrate. The polyol preferably comprises polymeric polyol in which a polyether polyol is graft-polymerized with a vinyl monomer, polyether polyol having a mass average molecular weight of from 400 to 1,000, in which a polyhydric alcohol is addition-polymerized with an alkylene oxide, and polyether polyol having a mass average molecular weight of from 2,000 to 4,000 in which a polyhydric alcohol is addition-polymerized with an alkylene oxide.

Abstract: A method of manufacturing a longitudinally extending composite structure including a shell part comprising a fibre reinforced polymer material including a polymer matrix and fibre material embedded in the polymer material is described. The shell part is manufactured in a closed mould comprising at least a first outer mould part having a first forming surface and a second outer mould part having a second forming surface. The method comprises the steps of: arranging a first fibre material in the first forming surface of the first outer mould part, arranging a pre-fabricated longitudinally extending reinforcement element, such as a beam or a web, on top of the first fibre material, arranging a second fibre material in the second forming surface of the second outer mould part, and sealing a polymer foil above the second fibre material so as to retain the second fibre material against the second forming surface.

Abstract: A drain pipe coupling for connecting a primary pipe having a primary width ?1 to two or more secondary pipes, said secondary pipes having a secondary width shorter than the primary width of the primary pipe, said drain pipe coupling having a cuff for connecting to the primary pipe and a transition portion connecting to the secondary openings; a downspout extension terminating in a collapsible, extendable and flexible low profile corrugated discharge pipe having a substantially symmetrical oblong cross section but not having any internal supports; a reducing insert adapter for connecting a 2 inch rectangular downspout to a 4 inch rectangular cuff comprising a first open adapter-end sized to engage with the rectangular cuff and a second open adapter-end sized to engage with the open end of said second rectangular gravity-flow drain pipe; and a gravity-flow drain pipe having a camouflage pattern displayed on a portion of the outer surface of the pipe.

Abstract: A composite tube is made by applying a mixture of individual reinforcing fibers and a resin onto the interior cylindrical wall of the spinning mandrel.

Abstract: A reconfigurable vehicle console having a plurality of interchangeable overlapping blank and equipment mounting face plates, including both tongue-and-groove joints between adjacent face plates, as well as optional lap joints.

Abstract: An inertial particle focusing system for use with a particle having diameter (a) includes a curved microchannel into a substrate, said microchannel having a radius of curvature (r), and a channel hydraulic diameter (Dh), wherein the ratio of r to Dh satisfies the following criterion: 2ra2/Dh3?0.037.

Abstract: A process and apparatus for producing perforated composite structures, such as acoustic skins suitable for aircraft engine nacelle and duct components. The process includes placing a mat member, a non-impregnated fabric member, and a resin film on a tool surface so that pins disposed on the mat member project through the fabric member and resin film to define holes therein. The fabric member is between the mat member and resin film, and the fabric member and resin film define a stack that conforms to the mat member and tool surface. A caul member is then placed on the stack so that apertures in the caul member are penetrated by the pins. The stack is heated to melt the resin film and cause molten resin to infuse the fabric member and yield a resin-infused fabric stack, after which the molten resin within the resin-infused fabric stack is at least partially cured.

Abstract: A vehicle panel (10) includes a core layer (12) and a layer of metalized film (14) bonded to the core layer (12). In one embodiment, the core layer (12) is made of a material with heat absorption or insulation properties. The layer of metalized film (14) is made of a material having heat reflective properties that can be bonded to the core layer (12). Alternatively, a compatible bonding agent can be applied to the core layer, the metalized film, or both. To form the vehicle panel (10), the layer metalized film (14) is positioned on one half of a mold tool and the core layer (12) is positioned on the other half of the mold tool. Heat is applied to the core layer (12) and the mold tool is closed such that the heat from the core layer (12) causes the metalized film (14) to be in a formable state and bonds to the core layer (12).

Abstract: A method for creating a material sheet with fibers includes the steps of feeding a layer of loose fibers to a conveyor; applying adhesive to the loose fibers, the adhesive being capable of mechanically bonding to the loose fibers; conveying the loose fibers and adhesive to a mold; and allowing the adhesive applied to the loose fibers to expand while containing the adhesive applied with the loose fibers in the mold in a manner to cause the adhesive to permeate throughout the fibers and to harden in a desired thickness.

Abstract: A production method of a metallic decorative sheet (10) which is insert-molded integrally with a thermoplastic resin molded body (20) to constitute an insert molded body (1) has steps of: laminating a specular ink layer (12) on one surface of a transparent thermoplastic resin film (11) in a region except an edge region serving as an edge portion of the insert molded body (1) and in a region for displaying a metallic design on an outer surface of the insert molded body (1), and laminating a non-specular ink layer (13) on the specular ink layer (12) and on the surface of the transparent thermoplastic resin film (11) where the specular ink layer (12) is not laminated.

Abstract: A sports footwear, particularly suitable for use in road and off-road bikes, including an outsole having means with differential stiffness, a heel cup made of at least a composite material with differential stiffness and a cushioning insert to be inserted into a padded tongue to achieve comfort and to customize said footwear, and a process to manufacture said footwear.

Abstract: A fiber reinforced panel is manufactured to include an integral vent screen. Holes are made in each of first and second sheets of fiber and the holes register with each other when the sheets are stacked within a mold. A screen material is placed between the first and second sheets so that a part of the screen material that registers with the holes in the first sheet and second sheet is exposed. Filler inserts are inserted into the holes of the first and second sheets to mask the screen. A resin is provided and cured to bond together the first and second sheets and the screen. Thus, the screen remains exposed after the first and second sheets and screen have been bonded together by the resin, thereby forming a fiber reinforced panel having an integrally molded vent screen therein.

Abstract: A thermoplastic pultrusion die system for pultruding a thermoplastic composite includes a first pultrusion die member; a second pultrusion die member; a die cavity gap formed between the first pultrusion die member and the second pultrusion die member; and a die cavity gap adjustment mechanism that imparts movement to at least one of the first pultrusion die member and the second pultrusion die member to vary the die cavity gap within a very tight die cavity gap tolerance.

Abstract: A method is described for making a composite laminate formed by curing a stacked structure comprising at least two layers of strips of fibrous material impregnated with resin, wherein the strips in adjacent layers have different directional orientations. An apparatus is provided for simultaneously separating a band of fibrous material impregnated with resin into strips and depositing the strips between adjacent pin rows of a pinmat to form the stacked structure.

Abstract: This invention provides single-step pultrusion processes for producing fiber reinforced polymer (FRP) articles that may have variable cross sections and/or non-linear shapes. This unique capability results from the use of two sets of dies to form the article. The first is a set of moving dies connected together to form mating continuous loops of moving die links to: a) draw the FRP material into the apparatus; b) shape the cross section of the FRP material; c) cut the FRP material to the appropriate length; and d) hold the uncut FRP material in position for the next production cycle. The second set of dies forms a guide path mounted on opposing conveyers. The guide path includes heated die segments to define a curing section that may be non-linear. Cycling the moving die links through the curing section and/or cycling the conveyers provides a straightforward method for automated production of finished pultruded articles with unique shapes.

Abstract: A urology catheter is provided that includes an elongated body extending from a proximal end to a distal end. The body defines at least one lumen. A tip has a proximal end that is disposed in abutting relation with the distal end of the body such that the body is fixed with the tip. The tip defines a lateral opening that is defined by a wall including an external radius disposed in transition with an outer surface of the tip and an internal radius disposed in transition with an inner surface of the tip. The external radius has a non-perpendicular profile with the outer surface of the tip. An expandable member has a proximal portion disposed about the body and a distal portion disposed about the tip. A method of manufacturing the urology catheter is provided.

Abstract: A three dimensional acoustic passive radiator diaphragm. A diaphragm a three dimensional volume. An acoustic driver radiates pressure waves into the three dimensional volume to cause the diaphragm to expand and contract. The three dimensional passive radiator may include a core of a porous, compressible material.

Abstract: The present invention provides a method for manufacturing a metal/composite hybrid wheel for a vehicle by molding an inner rim of a composite material by compression and, at the same time, bonding an outer rim of a metal material to the inner rim to induce compressive residual stress in the bonding area by a difference in thermal expansion coefficient between the outer rim and the inner rim, thereby increasing the adhesive strength of the bonding area and the durability of the wheel. The present invention further provides a metal/composite hybrid wheel for a vehicle manufactured by the method.

Abstract: An animal toy includes a compressibly elastically deformable hollow thin-walled elastomer core sealingly circumscribing a center, includes an exterior including a first gravure elastomer relief surface and a second surface, includes a wall less than about eight millimeters thick, and includes points on the exterior at varying distances from the center. A fabric cover is affixed to the second surface and has a selected thickness, the ratio of the thickness of the fabric cover to the thickness of the wall being in the range of 1:6 to 1:0.15. A line of demarcation separates the exterior into at least two areas.

Abstract: Methods and apparatus for bonding block of paraffin having cellular material embedded at one end thereof with an additional amount of paraffin are disclosed, including a method comprising placing the paraffin block in a well of a mold with the paraffin-embedded cellular material positioned on a support structure that elevates the cellular matter from a bottom surface of the well; heating the mold to thereby soften and at least partially melt and blend together the embedding paraffin and additional paraffin located in the well, the support structure sized such that some of the additional paraffin flows on the bottom surface of the well at least partially surrounding the support structure; and cooling the mold to thereby bond the additional paraffin to the embedding paraffin and re-solidify the paraffin block, wherein the retained cellular matter is spaced apart from an end of the re-solidified paraffin block defined by the bottom surface of the well.

Abstract: A roller ski includes a frame structure that is operatively connected to at least a rear wheel and a front wheel. The frame structure includes at least one beam member that includes an outer shell having a first non-metal material, and an inner core, which includes a second non-metal material.