Abstract: A laminated composite fabric material used for example in the manufacture of automobile air bags has at least one thermoplastic coating layer that is pressure laminated to a pre-treated fabric using an adhesive. The fabric, pre-treated with a curing agent such as an alkyl ether amine, resists penetration by the adhesive, resulting in a softer, more pliable composite fabric. The composite fabric also optionally includes a layer comprising a silicone polyurethane copolymer or acrylic cross-linked with a blocked isocyanate, which functions as a non-stick coating. The invention also relates to a method for manufacturing a laminated composite fabric.

Abstract: A hollow core composite assembly 10 is provided, including a hollow core base 12 having at least one open core surface 14, a bondable solid film 22 applied to the open core surface 14, at least one dry face ply 30 laid up dry and placed on top of the solid film 22, and a liquid resin 32 applied to the at least one dry face ply 30 and then cured.

Abstract: The present invention is directed to an inter-laminar adhesive composition containing a liquid epoxy resin, a polyfunctional epoxy resin having a softening point higher than a lamination temperature of the adhesive and with two or more epoxy groups within the molecule; and a latent epoxy curing agent initiating a reaction at a temperature higher than the lamination temperature. The adhesive composition optionally contains a liquid resin other than the liquid epoxy resin and/or an organic solvent and the liquid resin includes the liquid epoxy resin, the organic solvent or both constituting from 10 to 55% by weight of the composition. This inter-laminar adhesive composition allows for the preparation of a multi-layer printed wiring board. The process for preparing the multi-layer printed wiring board is provided.

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

Abstract: In a film with metal foil of the present invention, a metal foil is stuck to the surface of a resin film via an adhesive layer. The adhesive is formed by crosslinking an acrylic polymer obtained by the copolymerization of a (meth)acrylic acid ester with a carboxyl group-containing radically polymerizable monomer, with a polyfunctional compound having a functional group reactive with the carboxyl group. The film with metal foil is very useful for producing a multi-layer wiring board by the so-called transfer method. By using this film, there can be produced a multi-layer wiring board having a fine and highly dense wiring/circuit layer and having a very excellently flat surface.

Abstract: A method is provided for using a three-dimensional, Pi-shaped, woven preform to assemble first and second composite components. The preform is infused with resin, and at least one surface of the preform is adhered to at least one surface of the first component using a film adhesive. The preform is cured while an oversized tool coated with non-stick material is located within a clevis formed by two legs of the preform. A removable peel ply is located between the tool and the clevis, and semi-rigid over-presses are used during curing. After curing, the tool, over-presses, and peel ply are removed, and adhesive is injected into the clevis. The second component is inserted into the clevis, the adhesive adhering to an inner surface of the clevis and to at least one surface of the second component for retaining the second component within the clevis, the second component having a smaller width than the tool.

Abstract: A honeycomb sandwich panel is produced by (a) mounting a honeycomb core on a lower prepreg laminate skin placed on a forming die, (b) superimposing thereon an upper prepreg laminate skin to cover the honeycomb core, (c) mounting flat plate-shaped elastic jigs on a portion of the resulting assembly where the lower prepreg laminate skin and the upper prepreg laminate skin are overlapping each other, (d) superimposing flat plate-shaped press jigs on the elastic jigs, and (e) heating the assembly under pressure for adhesion forming.

Abstract: A system and method for forming structural assemblies with 3-D woven joint pre-forms. The method of the present invention forms complex structural assemblies with pre-formed structures. Adhesive is applied between the preformed structures and uncured 3-D woven textile pre-forms. Then together the preformed structures and uncured resin impregnated 3-D woven textile are cured with heat and/or pressure to form the larger complex structural assemblies.

Abstract: A process for forming a molded polymer resin fiber tube clamp, as well as the tube clamp formed by that process. Continuous top and bottom plies provide increased resistance to delamination/cracking as they sandwich a filler material. The tube clamp is free from exposed fiber ends so than no wear is produced on a tube being clamped.

Abstract: A method for increasing the adhesion of a first layer comprising a fluoropolymer substantially free of interpolymerized units derived from vinylidene fluoride to a second layer comprising a curable elastomer is described. The method comprises adding a dehydrofluorinating composition to the curable elastomer, contacting the layers and curing the layered article so formed. The resulting multilayer compositions and articles are also disclosed.

Abstract: A three dimensional soft magnetic metal mass suitable for milling is formed wrapping soft magnetic metal ribbon into a three dimensional shape and then applying adhesive to the three dimensional shape. The adhesive permeates the three dimensional shape. The adhesive is then cured. If the soft magnetic metal mass is made as a toroid, then it could be processed into an electromechanical component. The electromechanical component would then be suitable for use in very high frequency electric motors.

Abstract: A bladder with an anti-tack rubber having suitable curing properties to turn up plies in manufacturing pneumatic tires is provided. In a preferred embodiment, the anti-tack rubber comprises 50 to 45 parts natural rubber cured with 50 to 60 parts chlorosulfonated polyethylene, 0.9 to 1.1 benzothaizyl disulfide and 0.9 to 1.1 phenylenediamine. A method of making the anti-tack rubber comprises mixing a first rubber and an anti-tack composition and blending curing agents to form a workable anti-tack rubber with suitable curing properties. An improved and simplified method to form a bladder with suitable anti-tack and curing properties, and a method for using a bladder to turn plies in manufacturing pneumatic tires, wherein the bladder is made from an anti-tack rubber is also disclosed.

Abstract: A process for bonding a semi-crystalline or crystalline thermoplastic polymer to a thermosetting polymer component, the process including selecting compatible semi-crystalline thermoplastic polymer and uncured thermosetting polymer components wherein the curing temperature of the uncured thermosetting polymer components is above the melting temperature of the semi-crystalline thermoplastic polymer. The process includes locating the thermoplastic polymer in contact with the uncured thermosetting polymer component and heating the thermoplastic polymer and uncured thermosetting polymer or thermosetting polymer composite component to the curing temperature of the thermosetting polymer, where the uncured thermosetting polymer components and the thermoplastic polymer are able to at least partly interpenetrate before the thermosetting polymer cures.

Abstract: A method is provided for using a woven preform having a base and at least one leg extending from the base. The preform is used to assemble first and second composite laminate components formed from tape or fabric and a resin matrix. Z-pins are inserted into the first component prior to its being cured, forming a stubble extending above a surface of the first component. The uncured preform is placed on the surface of the first component, the stubble extending into the preform. The cured second component is attached to the preform. Over-wrap plies are optionally placed on the outer surfaces of preform. Adhesive is optionally placed between the preform and the first and second components. A vacuum bag and tooling are used while curing the preform to adhere the legs of the preform to the second component and the base of the preform to the first component.

Abstract: A moisture-reactive hot-melt adhesive composition, useful as an adhesive, is provided. The composition is particularly useful as an adhesive for bonding profile-wrap articles. Also provided are a method for making profile-wrap articles using the composition and the profile-wrap articles so made.

Abstract: The strength of wood composites, including hybrid composites comprising wood members bonded to reinforced polyester members, is improved by modifying the polyester components with a polyisocyanate. Wood composites adhesively bonded with polyester resins modified according to this invention are particularly desirable for use in applications where exterior exposure is contemplated.

Abstract: A method of fabricating an elastomeric structure, comprising: forming a first elastomeric layer on top of a first micromachined mold, the first micromachined mold having a first raised protrusion which forms a first recess extending along a bottom surface of the first elastomeric layer; forming a second elastomeric layer on top of a second micromachined mold, the second micromachined mold having a second raised protrusion which forms a second recess extending along a bottom surface of the second elastomeric layer; bonding the bottom surface of the second elastomeric layer onto a top surface of the first elastomeric layer such that a control channel forms in the second recess between the first and second elastomeric layers; and positioning the first elastomeric layer on top of a planar substrate such that a flow channel forms in the first recess between the first elastomeric layer and the planar substrate.

Abstract: A method of making the basic material and the facial skin of synthetic leather with one round of process includes two units of material injecting devices for respectively making a PU plastic foam layer and a face-skin layer at the same time. The PU plastic foam layer and the face-skin layer are tightly combined together when they are in a condition of half reaction and not fully becoming hardened to finish making the synthetic leather with one round of process, achieving effects of shortening a producing process, saving equipment, labor and electricity, lowering producing cost, and preventing air and water pollution.

Abstract: A hollow core composite assembly 10 is provided, including a hollow core base 12 having an open core surface 14, a polyetherketoneketone film 22 applied to the hollow core base 12, and an adhesive layer 24 positioned between the polyetherketoneketone film 22 and the open core surface 14. The resultant hollow core composite assembly 10 can be cured to provide a structure suitable for use within a liquid molding process.

Abstract: The adhesive material contains a radical-polymerizable compound, a curing agent, and a thermoplastic resin; gives a negative result of the Ames test; and has a PII, or skin irritation, value of 2 or less. In particular, all the starting ingredients should preferably give a negative result of the Ames test and have a PII, or skin irritation, value of 2 or less.

Abstract: The invention is to perform operations from sealing of a honeycomb core with a thermosetting sealing material having an adhesive property to its hardening in one step, prevent a resin from flowing into cells of the honeycomb core during resin impregnating operation, and thereby mold low-cost honeycomb sandwich components by using RTM technique which is adopted in molding solid materials, for instance. Dry fabric sheets are stacked on both sides of a honeycomb core with thermosetting sealing members having an adhesive property placed in between, and the sealing members and the dry fabric sheets are heated at the curing temperature of the sealing members to cause initial hardening of the sealing members and to dry the dry fabric sheets. Then, the dry fabric sheets are impregnated with a thermosetting resin and the resin impregnated into the dry fabric sheets is hardened by hot-pressing an entire assembly thus prepared under specific conditions.

Abstract: The present invention provides a method of manufacturing a wiring board, including the steps of forming a through hole on a prepreg having a releasing resin film on at least one of its surfaces, the prepreg being obtained by impregnating a porous film having a thickness of 5 to 90 &mgr;m and a porosity of 30 to 98% with a half cured thermosetting resin, filling the through hole with a conductive paste containing a conductive filler, peeling the resin film, laminating a metal foil on a surface from which the resin film is peeled, and heating and pressurizing the laminated product.

Abstract: Two-component systems are described which are suitable for underlining, adhesive bonding of the crimped fold and sealing of auto body sections, particularly for crimped fold sealing of add-on vehicle parts. The two-component systems attain the requisite grip strength for mounting the add-on parts on the body as well as the requisite strength and dimensional stability for the production process up to and with the CIP passage, within the predetermined cycle time, on the basis of cross-linking of the sealant composition twice. In one embodiment, the surface of the two-component system is pre-cross-linked by a UV-induced reaction and by the cross-linking of the two-component system to the extent of portability. In addition, two-component systems are described which cross-link intentionally only partially up to a consistency that permits a rugged course of the process through cleaning baths and which harden completely only by means of a further hardening process, for instance in the CIP forced circulation oven.

Abstract: A method of making erasable article comprises: providing an electret film having first and second opposed major surfaces; applying a polymerizable precursor composition to at least a portion of the first major surface; polymerizing the polymerizable precursor composition to form a non-tacky crosslinked polymeric layer; and exposing the electret film and non-tacky crosslinked polymeric layer to a direct current corona discharge, wherein the second major surface is free of adhesive material. Erasable articles and kits containing them are also disclosed. Also disclosed are dry erase articles having a first coating layer coated onto a flexible substrate. The first coating composition has a hardness upon curing of greater than about 500 MPa and forms an ink receptive writing surface suitable for receiving dry erase marker ink. The first coating layer has minimal effect on the flexibility of the sheet.

Abstract: A powder spray booth (2) with a powder recovery system having an overspray intake (18) communicating with the interior of the booth. A vertically extending duct (20) leads from the overspray intake to a powder recovery system such as, for example, a cyclone. The vertically extending duct may have doors (32) opening to the interior of the booth to provide access to the vertical duct for cleaning. The doors may have holes (120) to aspirate air from the booth interior to optimize air flow patterns within the booth. A diverter plate (26) within the booth (2) defines with the booth floor (10) a floor duct leading to the overspray intake (18). The diverter plate has apertures for allowing oversprayed powder to be collected through the plate.

Abstract: The present invention relates generally to a laminated tarp and a method of making this laminate. More particularly, the present invention relates to a laminated tarp containing multiple layers, including a fabric layer sandwiched between two layers of polymeric material comprising a vinyl (co)polymer and a polyurethane material. This laminated tarp can also include a thermosetting adhesive layer between the polyurethane material and the fabric layer, as well as a heat-sealable or weldable coating over the polyurethane material and/or over the vinyl (co)polymer layer. Also described is a method for making the laminated tarp.

Abstract: There is provided a duct and an associated preform and method. The duct is formed of a thermoplastic material and is lightweight, strong, flame and smoke resistant, and non-toxic. The duct is formed from a flat laminate and does not require a specialized, disposable mandrel for supporting conventional thermoset plies. Preferably, the duct is formed from a preform, which is cut according to the desired shape and size of the duct so that trimming after the duct has been formed is not required. Additionally, features such as holes and spud locations can be provided by cutting or marking the preform before forming the duct. Each duct can be formed of multiple articulated segments that are joined by connectors.

Abstract: A synthetic wood material and method are disclosed, including providing a plurality of continuous glass fibers oriented substantially in the longitudinal axis and coated with a resorcinol modified phenolic resin binder substantially free from catalyst. In one aspect, the synthetic wood material is oxidatively treated to restore color. In one aspect, the fibers and binder are precoated with a furfuryl alcohol resin prior to the pultrusion step to form the synthetic wood.

Abstract: A multi-layer tile material produced from layers of alumina enhanced thermal barrier material having different densities. The insulation layers are bound together by a high strength, high temperature alumina or silica binder having a coefficient of thermal expansion similar to that of the insulation layers. Use of the multi-layered tile allows the problems of tile slumping and of insufficient heat management associated with low density alumina enhanced thermal barrier tile to be overcome.

Abstract: A method for forming a dielectric structure. A first layer is formed, wherein the first layer includes a first fully cured photoimageable dielectric (PID) material. A sticker lays is nonadhesively formed on the first layer, wherein the sticker layer includes a partially cured PID material. A second layer is nonadhesively formed on the sticker layer, wherein the second layer includes a second fully cured PID material, wherein the sticker layer is nonadhesively sandwiched between the first layer and the second layer such that the sticker layer is in non-adhesive contact with the first layer and in non-adhesive contact with the second layer, and wherein the sticker layer is capable of remaining in non-adhesive contact with the first layer and the second layer until the sticker layer is subsequently subjected to additional curing.

Abstract: A method is provided to assemble flip chips to an electronic circuit using a printable anisotropic conductive adhesive or paste. The invention is especially useful to assemble flip chips or other components to an array of circuits provided within a large area format. The circuits in a preferred embodiment are disposable radio frequency identification devices (RFID) or Smart Cards.

Abstract: Hardened wear-resistant members are secured to an underlying body member in a manner to accommodate differing coefficients of thermal expansion. In one form a connector comprising shear compliant material is secured at one of its faces to the body member and a hardened wear-resistant member is secured to the opposite face of the connector. In another embodiment, the body member has adjacent portions resiliently connected to each other and the engaging member is secured at spaced locations to the two resiliently joined portions such that different thermal expansion of the two parts will be accommodated.

Abstract: A resin impregnated overlay is applied to a wood veneer, which in turn may be adhered to a substrate.

Abstract: The present invention provides a method of forming an abradable seal between rotating and non-rotating components of a machine. A sheet of abradable material is formed and then cut to a desired shape to form an abradable sheet piece. An adhesive composition is applied to at least a portion of a substrate surface and the sheet piece is contacted with the adhesive composition to adhesively bond the sheet piece to the substrate to form the abradable seal. An abradable seal is also provided having an adhesive composition deposited over at least a portion of a substrate surface with an abradable sheet piece bonded to the substrate by the adhesive composition.

Abstract: A system for permanently associating identifying indicia with a previously manufactured product. Silicone sheet material having imbedded therein a quantity of thermally activatable crosslinking catalyst is secured to the product. An indici-containing element is placed on the silicone sheet material and is then covered by another piece of the same type of silicone sheet material. Heat is then applied to the assembly to cause the pieces of silicone sheet material to crosslink together and encapsulate the indicia-containing element.

Abstract: A method of production of veneer assemblies is provided wherein a thermocurable adhesive is placed along the joint between adjacent veneer sheets and a core substrate and subjected to heat pressing to bond the veneer to the core substrate.

Abstract: A method is provided for improving the bond strength and quality between a borate-treated wood material and a phenolic resin in a wood composite product, the method having the steps of bonding the wood material with an adhesive system comprising the resin and an additional base, the base providing a substantial increase in the alkalinity of the adhesive system over that provided by the resin, the increase sufficient to limit the bonding of borate molecules with the phenolic resin molecules to such an extent as to allow a substantially complete cross-linking of the phenolic resin molecules to occur. An adhesive system is also disclosed for use in the production of wood composite products.

Abstract: A method of manufacturing articles utilizing a composite material having a high density of small particles such as microspheres in a matrix material is disclosed. In accordance with one aspect of the present invention, at least first and second layers of flanking material are disposed in a generally non-parallel relationship with respect to each other and then are pulled through a die. While the flanking material layers are being pulled through the die, a composite material is injected into a space defined between the at least first and second layers of flanking material. The composite material and the at least first and second layers of flanking material are heated as they pass through the die to cure the composite material and bond the at least two flanking material layers to the composite material, thereby forming a cured article.

Abstract: Disclosed are a method for manufacturing a solid polymer electrolyte film/electrode composite, in which a porous electrode made from an electochemically active substance is used as an electrode and the pressure inside the porous electrode is reduced in order to fix the solid polymer electrolyte (SPE) film or pre-solid polymer electrolyte (pre-SPE) film to the porous electrode, a battery obtained by impregnating the electrode in the solid polymer electrolyte film/electrode composite with an electrolytic solution under reduced pressure and a method for producing such. The invention provides a thin, uniform film-shaped solid polymer electrolyte/electrode composite with ease. The battery fabricated with the composite is free of defects such as short, has high performance and, hence, is useful.

Abstract: A method of laminating a graphic sheet of material onto a substrate material, including the steps of positioning a substrate material, having a top and sides, into a desired position, disposing (a) at least one sheet of thermo-setting adhesive on the top of the substrate material, disposing (b) at least one opaque white melamine sheet on the at least one adhesive sheet, disposing the (c) graphic sheet of material on the at least one opaque white melamine sheet, disposing a (d) at least one clear sheet of melamine on the graphic sheet of material, disposing a (e) at least one release paper sheet on the at least one clear sheet of melamine, applying heat to the sheets a, b, c, d and e, and applying pressure to force said sheets a, b, c, d and e against the substrate to thereby cause bonding of said sheets a, b, c and d together and to the substrate. A preferred product produced by the method is formed with a ceramic tile as the substrate and a printed paper sheet as the graphic sheet of material.

Abstract: The invention relates to a method for attaching a semiconductor chip to an ink jet pen body and improved construction techniques therefor. According to the method a first adhesive have a cure time greater than about 15 minutes is dispensed in a predetermined pattern in one or more chip pockets of an ink jet pen body. Beads containing a second adhesive are dispensed in two or more discrete locations around an inside perimeter of each chip pocket. A semiconductor chip having chip edges is attached to the second adhesive in each of the chip pockets and the first adhesive is cured using heat or radiation. Use of a dual adhesive system improves the alignment of the semiconductor chips relative to one another until the first adhesive is completely cured.

Abstract: A high Tg acrylic polymer is provided as well as an epoxy-blend thereof for use as a pressure sensitive adhesive. The high Tg acrylic polymer comprises a copolymer of an alkyl (meth)acrylate monomer having a Tg>20° C., a C1-30 (meth)acrylate monomer, an nitrogen-containing polar monomer, and a polymerizable epoxy-containing monomer, with the polymer having a Tg>50° C. When blended with an epoxy resin, the resulting mixture exhibits desirable pressure sensitive adhesive properties and may be thermocured.

Abstract: A method for adhering a friction material for a lockup clutch, with which a friction material is adhered to a flat surface of a core plate, comprises a disposing step of disposing the friction material between a heated member and the flat surface of the core plate, a pressing/heating step of bringing the heated member into contact with the core plate and applying load to the core plate by a plurality of pins from a back side opposite to the flat surface of the core plate, and a step of maintaining a state under the above-mentioned pressing/heating step for a predetermined time.

Abstract: A method for installation of a flexible resin impregnable liner for lining a lateral pipe which leads into a main pipe having at one end a flexible collar for installation at the location where the lateral liner meets the main, wherein after installation the collar extends along the interior of the main seating against the opening of the lateral. The flexible liner is installed by inserting the liner into the lateral pipe and using fluid under pressure to expand the lining against the lateral wall to form seals with the collar at the lateral/main pipe junction.

Abstract: An unvulcanized raw rubber is provided, to which magnetic ferrite powder is added. A resulting mixture composed of the unvulcanized raw rubber and magnetic ferrite powder is passed through a rolling machine or an extruding machine such that the mixture is formed into a sheet blank that contains the magnetic ferrite powder aligned regularly in a particular orientation. Alternatively, the resulting mixture may be first passed through an extruding machine and then through a rolling machine. The sheet blank is then stamped across a planar direction such that a ring-like sheet is formed. The ring-like sheet, along with a supplemental ring, is placed inside a metal mold, where the ring-like sheet and supplemental ring are compressed in an axial direction, while applying heat thereto, so that the ring-like sheet is vulcanized and joined to the supplemental ring. Finally, the vulcanized ring-like sheet is magnetized so that S poles and N poles appear alternately around its circumference.

Abstract: An object of the present invention is to completely cure a resin composition highly capable of screening energy radiation, such as a carbon fiber-reinforced composite material (CFRP), simply by exposing the resin composition to UV radiation in the presence of a specific photopolymerization initiator system (reaction catalyst system) comprising at least two components. To this end, the present invention provides a resin curing method wherein, when a resin composition is exposed to energy radiation typified by UV radiation, another kind of first energy than the energy from an energy radiation source is autogenously generated within the resin, and the same kind of second energy is successively generated by the autogenously generated energy, so that the resin composition is cured by means of the first and second energies, or both the first and second energies and the energy from the energy radiation source, whether or not the resin composition contains a substance capable of screening energy radiation.

Abstract: A formaldehyde-free aqueous binder comprising A) a free-radically polymerized polymer containing from 5 to 100% by weight of units derived from an ethylenically unsaturated acid anhydride or from an ethylenically unsaturated dicarboxylic acid whose carboxyl groups can form an anhydride group, and B) an alkanolamine having at least two hydroxyl groups, is useful as binder for renewable raw materials in the form of fibers or chips to produce shaped articles.

Abstract: A process for transferring a decorative sublimation dye design formed on a transfer sheet to a continuous laminate by applying a sheet of cellulose web material impregnated with a thermosetting resin to a surface of a backer sheet to form a pre-laminate. A release sheet is applied to the exposed surface of the sheet of cellulose web material. The transfer sheet bearing the decorative sublimation dye design is applied to the exposed surface of the release sheet. Heat and pressure are applied to the pre-laminate layered with the release and transfer sheets, causing the cellulose web material to seep into the pores of the backer sheet to form a thermofused continuous laminate, and causing the design on the transfer sheet penetrates the thermofused continuous laminate through a sublimation process. The release and transfer sheets are then separated from the thermofused continuous laminate showing the transferred design.

Abstract: Curable compositions that comprise two separately curable chemistry sets or compositions with curing temperatures sufficiently separated so that one chemistry composition can be fully cured during a B-staging process, and the second can be left uncured until a final cure is desired, such as at the final attach of a semiconductor chip to a substrate.

Abstract: An antireflection film and method of making same includes a substrate having a first surface and a second surface, the substrate being a circular polarizer, a linear polarizer, or a louvered plastic film, an inorganic layer deposited on the first surface of the substrate, and an optically active polymer layer formed by curing a curable composition in situ on the inorganic layer, the polymer layer having a refractive index not greater than about 1.53 over the wavelength range of 400 nm to 700 nm and a thickness of from about 20 nm to about 200 nm.