Abstract: A multilayer film useful for making plastic adhesive labels for glass substrates such as glass bottles. The multilayer films contain a base layer, an adhesive layer, and optionally an intermediate layer to improve interlayer bonding between the base layer and the adhesive layer. The adhesive layer comprises a heat-activated thermoplastic adhesive that is not tacky at room temperature. Films of the present invention are sufficiently non blocking at room temperature so as to not require the use of a separate release liner. The film can be utilized in conventional graphics printing operations and made into labels. Labels made from films of the present invention can be thermally adhered to glass substrates and exhibit sufficient adhesion to glass substrates to withstand washing/rinsing, filling, and pasteurization processes utilized in the bottling industry.

Abstract: A plastic smart card, such as a card having a radio frequency identification (RFID) proximity function, including at least one electronic element embedded therein and a physical contact card function and the hot lamination process for the manufacture of this dual function smart card and other plastic cards including a micro-chip embedded therein. The process results in a card having a preferred overall thickness in the range of 0.028 inches to 0.032 inches with a surface suitable for receiving dye sublimation printing--the variation in card thickness across the surface should not exceed 0.0005 inches. A card manufactured in accordance with the present invention also complies with all industry standards and specifications. Also, the hot lamination process of the present invention results in an aesthetically pleasing card. The invention also relates to a plastic card formed in accordance with the hot lamination process of the present invention.

Abstract: A method and apparatus for manufacturing prestressed piezoelectric actuators which maximizes output, and increases the precision and efficiency with which the multi-layer actuators are made. Individual layers of the piezoelectric actuators are automatically stacked and registered with respect to each other within press members prior to bonding the layers to each other with a thermoplastic adhesive. Compressive force is applied while heat is conductively transferred from a heating element to the actuator in order to raise the temperature of each of the layers above the melting point of the thermoplastic. The temperature of the heating element is then decreased until the temperature of the actuator layers drops to below the melting point of the thermoplastic adhesive, thereby bonding the layers. Compressive force is then released, and the actuators are removed, further cooled and polarized.

Abstract: A method of producing a thermal transfer image recording sheet is provided including the steps (a) bonding a surface of a substrate sheet to a plastic film through a layer of a polymeric binder having a glass transition temperature of 50.degree. C. or less to form a first laminate; (b) heat setting the first laminate under pressure at a temperature higher than the glass transition temperature of the polymeric binder layer to remove stress from the finished thermal transfer image recording sheet; and (c) forming a thermal transfer image-receiving layer on an exposed surface of the plastic film to produce the thermal transfer image recording sheet. A method of producing a thermal transfer image recording sheet is also provided including the steps (a) bonding a surface of a substrate sheet to a plastic film through a layer of a polymeric binder having a glass transition temperature of 50.degree. C.

Abstract: A laminate of an oriented resin film and a metal sheet substrate is used in the manufacture of can stock, the intensity of orientation of the resin film being greater along the bottom of the can and lesser along the can side wall. This construction is obtained by locally cooling, during lamination, that part of the heated metal substrate which will become the bottom wall of the resultant can.

Abstract: The present invention relates to a continuous vacuum lamination treatment method including the steps of stacking a back side covering member, a first filler member, a member to be sealed, a second filler member, and a surface side covering member in the named order to form a stacked body. The method further includes decompressing an interior region of the stacked body which is sandwiched by the surface side covering member and the back side covering member, and subjecting the stacked body to heat treatment at a desired temperature, in the named order. The stacking step is conducted on a plurality of vacuum lamination instruments having a structure capable of vacuuming the interior region therein and capable of being stacked vertically with adjacent stacked vacuum lamination instruments in contact.

Abstract: A process for the manufacture of a rim preform or rim-element having an axis of revolution by the placing on a preforming matrix pre-assembled fibers along two orientations defining deformable meshes. A winding of a strip of fibers is fastened on a circumference of the preforming matrix with asymmetrical orientation of the fibers, whereupon it is applied progressively until covering the entire surface of the preforming matrix by subjecting it to tensions of substantially circumferential orientation.

Abstract: A method of making a seat (10) includes preassembling the seat by positioning a seat cover (26) over a contoured foam substrate (18) with a layer of heat activated adhesive (24) between the seat cover and the foam substrate. Securing the seat preassembly (10') in a fixture (106) and introducing heating fluid into the fixture to pressurize a flexible bladder (156) against the seat. The pressurized bladder urges the seat cover against the contoured foam substrate and heats the adhesive layer. Next, cooling fluid is introduced into the fixture to pressurize the flexible bladder against the seat, and the pressurized bladder urges the seat cover against the contoured foam substrate and cools the adhesive layer.

Abstract: The present invention includes a method for sealing a discontinuity in the surface of a substrate comprises the steps of: (a) placing over the discontinuity an article comprising (i) a melt-flowable composition characterized by a first width, and (ii) a shaped, polymeric cap having a pre-selected, cross-sectional profile characterized by a second width and a shape in which the thickness of the cup across its width, the width of the cap, or both the width and thickness of the cap vary; (b) heating the article to cause the melt-flowable composition to flow and seal the discontinuity, where the cap controls the melt-flow behavior of the melt-flowable composition to substantially confine the melt-flowable composition to the area underneath the cap; and (c) allowing the article to cool while substantially retaining the pre-selected cross-sectional profile of the cap. The present invention also includes various articles for use in the method.

Abstract: A method is described for mounting an electronic module in an opening in a card body using pressure and heat. To avoid the thermal load on the electronic module and the card body during the relatively short heating-up phase in a fixed-cycle production process, the method is divided into several method steps, whereby either the heating of the electronic module and the card body and optionally a thermally-activable adhesive takes place in several method steps, or a thermally activable adhesive is heated selectively in a first method step and the mounting of the electronic module takes place under pressure or under pressure and heat in a second method step.

Abstract: The present invention relates to a process for the continuous production of a multi-layer web comprising an exterior covering and a nonwoven material disposed underneath. According to the present invention, a nonwoven material which has been prebonded is used as the starting product, and the steps of additional bonding, calibrating, and smoothing of the nonwoven material and of laminating the nonwoven material and the exterior covering are combined in a single process. The present invention, in addition to achieving a cost advantage, also produces a covering material that provides better sitting conditions, equivalent to the foam backed covering materials with respect to physical textile values yet being easier to recycle and. In addition, recycled textile products can be worked into the covering material of the present invention as reprocessed fibers without losing any advantage.

Abstract: A high pressure laminate is made of several layers of paper, including from bottom to top core sheets, a decor sheet and an overlay sheet. The core sheets are either composed of cellulose fibers or composed of 30 to 90 weight percent cellulose acetate fibers and 70 to 10 weight percent cellulose fibers. The core sheets are respectively coated with either a lamination polymer or a plasticizer. The decor sheet is composed of a mixture and a conventional amount of paper making dye. The mixture comprises 30 to about 90 weight percent cellulose acetate fibers, 10 to 70 weight percent cellulose fibers and 0 to 20 weight percent fillers. The decor sheet is coated with a plasticizer. The overlay sheet is composed of cellulose fibers and is coated with a lamination polymer. Upon application of heat and pressure to the several layers a laminate is formed having thermoplastic properties, improved postformability and a significant reduction in the release of volatile organics during formation.

Abstract: The present invention provides compositions and processes wherein recycling of waste carpets and textiles is achieved by coating the individual yarn fibers with a low viscosity adhesive that is dispersed or dissolved in a suitable solvent to affect coverage of the fine fibers, and arranging the coated fibers in layers to affect the most desirable physical properties and then cured to provide a high modulus matrix for the coated fibers in the laminate structure. The fibers may be from unshredded or shredded waste carpets, shredded waste woven or non woven fabrics, fabric bits, and knitted fabrics. When the carpet is used in an as received condition, the face yarns, which may contain one or more components yarns, are coated and the carpets are arranged in a sandwich construction wherein the backings of the two carpets are placed back-to-back, e.g., (F-B-(B-F).sub.

Abstract: A method and apparatus for bonding a cover (22) over the undulating surface of a foam cushion (10) includes placing the foam cushion (10) on a tool (18), piercing the cushion (10) with a plurality of needles (44), lifting the needles (44) to lift the cushion (10) as the cushion is frictionally retained on the needles (44), heating ambient air and ejecting the hot air from the needles (44) and into the cushion to elevate the temperature of the cushion. A compression plate (58) with holes (60) extending therethrough is disposed against the backside of the cushion (10) with the needles (44) extending through the holes (60). The needles (44) with the cushion (10) thereon are lowered to place the undulating surface of the cushion against an adhesive film (82) on the backside of the cover (22) so that heat is transferred from the cushion (10) to melt the adhesive.

Abstract: Multilayer material, essentially without adhesives between the various layers, particularly with two or three layers, consisting of at least one layer of aliphatic polyamide and at least one layer, alternating with the polyamidic layer, of vulcanized acrylic rubber, the above materials being characterized by a peeling strength (between the polyamidic layer and the vulcanized acrylic rubber layer) of more than 5 daN/cm.The process for the preparation of the above material is also described.

Abstract: A method for manufacturing a laminate includes steps of forming a laminated combination of synthetic resin sheet material with a metal foil laminated each other, thermoforming under a pressure the laminated combination while supplying an electric current to the metal foil, and, after termination of the current supply, cooling thus obtained laminate while further applying a pressure, whereby the laminated combination can be uniformly heated into its core part to allow the laminate of uniform quality to be obtained, while shortening manufacturing lead time and minimizing surface roughness.

Abstract: A planar porous composite structure including a plurality of regular textile planar layers formed of continuous yarns. The layers are placed on top of each other to form a structure having two dimensions at right angles to each other and a third dimension perpendicular to them and defining a plane having a direction along the two dimensions. A plurality of openings extends through the layers. Each opening is defined by portions of the continuous yarns extending substantially in the direction of the plane and existing in the regular textile planar layers to make the planar layers regular in structure prior to placing them on top of each other. A plurality of passages extends entirely through the structure in a direction substantially perpendicular to the plane of the structure.

Abstract: A patterned fibrous web and a process for making the patterned fibrous web are disclosed. The patterned web includes a plurality of functional particle-loaded areas forming a pattern of functional particles. Beneficially, when cut, the patterned fibrous web does not release functional particles from the cut edges.

Abstract: A tagged packet carries a tag which is attached to the main body of the packet by a thread. The thread comprises polypropylene so as to be attachable by heat sealing to the body. The body is made up of layers of sheet material also comprising thermoplastic material to allow the body to be closed by heat seals. The thread is secured to the face of the body at one edge at the same time as that edge is heat sealed and the heating for the thread seal is applied from the opposite face of the body whereas the adjacent regions of edge seal spaced from the thread has the heating applied through the first face. This arrangement gives closer control of the different conditions required for securing the thread and for sealing together only the sheet material of the body.

Abstract: Multi-functional materials are classified into those which have a photocatalytic layer 2 with a photocatalytic function directly disposed on the surface of a base 1 and those which have a photocatalytic layer 2 with a photocatalytic function disposed on the surface of a base 1 through a binder layer 6 interposed therebetween. Photocatalytic particles of the photocatalytic layer 2 are joined together by a surface energy or solid-state sintering. The photocatalytic layer 2 may have a structure in which fine particles fill interstices defined between photocatalytic particles or a structure in which no fine particles fill interstices defined between photocatalytic particles. A metal such as Ag, Pt, or the like may be fixed or not fixed to surfaces of the photocatalytic particles.

Abstract: In a method and molding apparatus for laminated molded bodies, a thermal-molding felt and a thermoplastic resin sheet, respectively in hot and soft condition, are set or placed on a mold face of a cold-pressing-molding lower mold. A cold-pressing-molding upper mold lowers onto the lower mold to press the thermal-molding felt and the thermoplastic resin sheet. Simultaneously, cooling air is supplied to center portion of the thermal-molding felt through a blowing pipe protruding from mold face of the thermal-molding felt side and intruding into the felt accelerating circulation of cooling air and cooling of the thermoplastic resin sheet.

Abstract: A method and apparatus (84,94) for controlling an assembly for bonding a cover (22) over the undulating surface of a foam cushion (10) controls a tool actuator cylinder (80) to tilt a tool (18) to a loading position to permit placing the cover (22) and an adhesive layer (82) on the tool, tilts the tool to a working position to permit placing the cushion on the tool, controls a plate actuator cylinder (62) to lower and raise a compression plate (58) to force air from an interior of the cushion, controls a ram actuator cylinder (90) to lower a ram (14) to pierce the cushion with a plurality of hollow needles (44) attached to a plenum chamber, controls a heater (38) to heat compressed air and eject the hot air from the needles into the cushion to elevate the temperature of the cushion and melt the adhesive, and lowers and raises the compression plate to force hot air from the interior of the cushion to cure the adhesive and bond the cover to the cushion.

Abstract: Spaced seams in a disposable garment web containing a plastic component and moving rapidly along a direction of manufacture is formed by bringing an ultrasonic welder into pressurized contact with the machine web for a predetermined period of time, heating the web along the seam for a first segment of the predetermined period of time and then maintaining pressurization with the ultrasonic welder during a second segment of the predetermined time period without heat sufficient to permit the plastic material to resolidify.

Abstract: A solar cell module comprising at least one solar cell element and at least a front surface covering material disposed to cover the light receiving face of said at least one solar cell element, said surface side covering material comprising a light transmissive resin and a light transmissive surface protective film situated on the outermost surface in contact with said light transmissive resin, characterized in that said front surface side covering material includes means for forming a desired display pattern on the light receiving face of said at least one solar cell element, said means comprising (a) a patterned surface region forming said desired display pattern and (b) another patterned surface region having a surface pattern which is different from that of said patterned surface region (a), and said patterned surface region (a) and said patterned surface region (b) being situated next to each other.

Abstract: A novel, high performance yet permeable, tough, fibrous structure, and a process for making the structure are disclosed. The fibrous structure includes a stabilized microstructure of improved uniformity of fiber and particulate distribution. Beneficially, the fibrous structure is of improved structural integrity and stiffness, as a result of being reduced in thickness.The process includes the steps of dry forming a fibrous web including crimped staple composite fibers, thereafter distributing and entrapping the functional particles in the web, and thereafter heating the fibrous web to form a microstructure-stabilized fibrous web. According to the process, the microstructure-stabilized fibrous web is thereafter by an additional heat treating step carried out without application of pressure to the web, heated to a thermoforming temperature, and thereafter the heated web is reduced in thickness and yet microstructural relative geometry is maintained. IR heat may be used.

Abstract: A method for producing laminated integrated circuit cubes includes applying conductive heat to the cube using at least one conductive heating device. A vacuum is created around the cube to remove air and other gases from between the integrated circuit layers prior to curing. A force is applied to the cube while it is heated under vacuum. A cooling gas is then circulated over the cube. Temperature and force sensing can be performed, and the process can be controlled by programmable logic controllers and the like.

Abstract: A process and apparatus for bonding together two layers of dissimilar material, yielding a composite structure which is substantially stress-free at a selectable reference temperature and reference isostatic pressure, which includes providing a first layer and a second layer; determining a critical line for the first layer and second layer in a pressure-temperature plane wherein a location of the critical line depends on the selectable reference temperature and reference isostatic pressure and depends on coefficients of thermal expansion and bulk moduli material constants of the first layer and the second layer, wherein the critical line sets forth a plurality of temperature-pressure pairs at which the composite structure will be substantially stress-free; controlling a temperature and an isostatic pressure during bonding such that the temperature and the isostatic pressure represent a point on the critical line; bonding the first layer and the second layer at the temperature and the isostatic pressure; and r

Abstract: A high pressure laminate is made of several layers of paper, including from bottom to top core sheets, a decor sheet and an overlay sheet. The core sheets are either composed of cellulose fibers or composed of 30 to 90 weight percent cellulose acetate fibers and 70 to 10 weight percent cellulose fibers. The core sheets are respectively coated with either a lamination polymer or a plasticizer. The decor sheet is composed of a mixture and a conventional amount of paper making dye. The mixture comprises 30 to about 90 weight percent cellulose acetate fibers, 10 to 70 weight percent cellulose fibers and 0 to 20 weight percent fillers. The decor sheet is coated with a plasticizer. The overlay sheet is composed of cellulose fibers and is coated with a lamination polymer. Upon application of heat and pressure to the several layers a laminate is formed having thermoplastic properties, improved postformability and a significant reduction in the release of volatile organics during formation.

Abstract: The present invention relates to methods for bonding articles made of polymers, and in particular, fluoropolymers. According to a first embodiment of the present invention, the method comprises the steps of coating the surface of either one or both of the articles to be bonded with a third polymer so that one or both of the articles has a layer of the third polymer adhered thereto, and bringing the articles into contact with each other after the articles are coated in order to bond the articles together. According to a second embodiment, the method comprises the steps of placing a composite layer comprising either conductive or magnetic materials, or both, between the articles, bringing the articles and the composite layer into contact with each other and electromagnetically heating the composite layer to bond the articles together.

Abstract: A method and apparatus (84, 94) for controlling an assembly for bonding a cover (22) over the undulating surface of a foam cushion (10) by controlling a ram actuator cylinder (90) to lift a ram (14) to permit placing the foam cushion (10) on a tool (18), lowering the ram (14) to pierce the cushion (10) with a plurality of needles (44), lifting the ram (14) to lift the cushion (10) which is frictionally retained on the needles (44), controlling a heater (38) to heat ambient air and ejecting the hot air from the needles (44) into the cushion (10) to elevate the temperature of the cushion. A pair of plate actuator cylinders (62) are controlled to dispose a compression plate (58) with holes (60) extending therethrough against the backside of the cushion (10) with the needles (44) extending through the holes (60).

Abstract: A self-supporting filter unit having at least one passage (10) defined by wall portions (12) made from air-permeable fiber fabric, through which wall portions air can pass and be drawn off along the passage but which prevent the passage therethrough of dust and/or other debris carried by such air, in which the passage is closed off at one end portion and at the other end portion there is formed integral with said wall portions a rigid mounting portion (16) into which the passage (10) opens whereby the filter unit can be supported as part of a filter assembly, wherein the mounting portion (16) includes a first reinforcing portion (18) of material around and secured with said fabric of the wall portion parts of the first reinforcing portion and fabric integral therewith remote from said one end being outwardly flanged, and wherein the mounting portion (16) further includes a second reinforcing portion (20,21) of material positioned over the outwardly flanged portions and secured thereto, said second reinforcing

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

Abstract: A method of making a board in which a thermoplastic layer is joined to the surface of a wooden board includes the steps of gluing a particle layer onto the surface of a wooden board, covering the particle layer with a thermoplastic, melting the thermoplastic and cooling the melted thermoplastic to form the thermoplastic layer. The particles in the particle layer are wood-based particles such as wood fiber, dust, chips, and paper chaff and are used in a quantity of from 10 to 500 g/sq.m.

Abstract: Resilient floor coverings are disclosed wherein the wear layer is a polymer composition, prepared from an ionomer resin and a polyfunctional olefinic compound, such as a polyfunctional acrylate. These floor coverings have good visual appearance and good burn, abrasion and stain resistance.

Abstract: Press-type apparatus for thermally bonding thermoplastic sheet material workpieces is provided with a pair of opposed platen assemblies which each include an inflatable set of compliant diaphragm members, a pair of opposed heat sources which may be brought into and retracted from contact with the diaphragm members, and a source of pressurized fluid for inflating the diaphragm sets and for cooling the heated workpieces. The method for operating the press-type apparatus basically involves both heating and cooling the assembled workpieces while they are simultaneously being retained in a condition of being clamped by the inflatable sets of the diaphragm members.

Abstract: A nonwoven abrasive or scouring article having at least one major surface and an interior region comprises an open, lofty web of first and second crimped, staple organic thermoplastic fibers, wherein the first organic thermoplastic fiber comprises materials selected from the group consisting of polyamides, pololefins, and polyesters, and wherein said second organic thermoplastic fiber comprises at least two materials of different heat stability. The first and second organic crimped, staple thermoplastic fibers are melt-bonded together at least at a portion of points where they contact. At least a portion of the first and second fibers of one major surface of the nonwoven article have an abrasive coating bonded thereto, and at least a portion of the first and second fibers of the interior region have no abrasive coating bonded thereto, a structure which minimizes the amount of binder which must be used.

Abstract: A method for bonding a cover fabric to a cushion body to form a seating component, preferably a seat cushion of a vehicle seat assembly, includes the step of supplying a heated atmosphere, preferably steam under pressure, to a forming tool of a forming apparatus, the forming tool diffusing the heated atmosphere and passing the heated atmosphere out of the tool, through the cover fabric, and into the cushion body to melt an adhesive layer between the cushion body and the cover fabric, while the cushion body and cover fabric are subjected to a pressurized environment, preferably by locating the forming apparatus, the cover fabric, and the cushion body in a pressure chamber maintained at relatively high pressure.

Abstract: The present invention provides a method of manufacturing high quality laminated veneer lumber from pre-flattened wood veneer, for such uses as in architecture and furniture, and a method of mass production thereof using veneer which is flattened in advance. A sheet of veneer is first obtained by cutting a log with a rotary lathe or the like, and flattening and cutting the veneer into a predetermined length. Sheets of veneer thus obtained are cut on both edges in the grain direction to form symmetrically diagonal end faces, and are bonded with one another at these end faces with their grain directions aligned to form an elongated sheet of veneer. The resultant elongated sheet veneer is cut into a predetermined length to form laminated veneer material having seams. Plural sheets thus formed laminated veneer material are laminated and bonded with their grain directions aligned to form laminated veneer core.

Abstract: A security device is described that is simple and reliable. It includes a base member which is adhesively attached to the surface of a large object such as a motor vehicle. A protective knife-edged boss surrounds and protects the adhesive to defeat attempts to pry the base member off the vehicle. Housed within the base member is a steel tube, and a locking cable extends through the tube to secure personal property. A cavity is provided for easy installation of the tube within the base member, and a flange is attached to the tube for preventing extraction of the tube from the base member, as well as defeating removal of the base member from the vehicle. A three-way system of adhesion is employed which provides superior results.

Abstract: A security device is described that is simple and reliable. It includes a base member which is adhesively attached to the surface of a large object such as a motor vehicle. A protective knife-edged boss surrounds and protects the adhesive fastener to defeat attempts to pry the base member off the vehicle. Housed within the base member is a steel tube or band, and a locking cable extends through the tube or band to secure personal property. A cavity is provided for easy installation of the tube or band within the base member, and one or more flanges are attached to the tube or band for preventing extraction of the tube from the base member, as well as defeating removal of the base member from the vehicle. The band and flanges may be formed from a single stamping. A three-way system of adhesion is employed which provides superior results.

Abstract: A plastic laminate includes an acrylic sheet and layer of paint disposed thereon. A polyester sheet has a layer of adhesive disposed thereon. The adhesive layer is bonded directly to the paint layer. The laminate is formed by applying the paint layer to the acrylic sheet and thoroughly drying the paint layer. The polyester sheet is heated to a temperature to melt the hot melt adhesive and the heated adhesive is applied to the paint layer under pressure while the paint layer is being cooled. The entire laminate is then also cooled to room temperature under pressure.

Abstract: A device for electronically seam fusing similar or dissimilar multiple polymeric materials by placing the materials between two opposing plates, wherein the plates have cooling tubes disposed within the plates and have the required combination of heating elements, non-stick heat barriers, and configuration enhancers disposed thereon. The opposing plates are then closed by a force which is regulated by a control feature which also governs the timing, length and temperature that is utilized by the heat elements and cooling tubes of the invention. Upon completion of the electronic seam fuse cycle, the multiple layers of polymeric materials are fused together, and separated if desired, thus creating a seam that is as strong or stronger than the individual material. The selection of seam fusing process parameters is determined by employing an optimization process that considers the impact each process parameter has in combination with one another.

Abstract: The invention concerns a process and equipment for manufacturing laminated photovoltaic modules, where (a) a module-stack (2) formed by the system of solar cells, the encapsulating materials and the separating foils is deposited at the loading station (1) and where (b) the module-stack (2) is moved into the vacuum laminator (5) which thereupon is closed and evacuated, and, by pressing the heater plate (21) against the thermally conductive carrier plate (3), said stack is heated to the softening point of the plastic sealing layers present in the encapsulating materials, and where (c) following airing of the vacuum laminator (5) the heater plate (21) is not cooled and the formed composite (2') is moved into the hardening oven (10) and where (d) the hardened laminate (2") is then moved into the cooling zone (12) and (e) is removed from the manufacturing process at the removal station (14). The process stages (a) through (e) of the invention are carried out simultaneously and parallelly in timed manner.

Abstract: A composite integral sheet of wrap material which includes a first layer of absorbent material containing fibers bearing foraminous hydrophobic water-vapor-permeable pellicles, a second layer of printable material and an impermeable pigmented polymer layer interposed between the first and second layers. Additionally, the absorbent layer will include highly absorbent material formed by in-situ crosslinking of a partially pre-neutralized polyacrylic acid. The composite wrap material has a plurality of air pockets formed between at least one of the first or second layers and the polymer layer, by discontinuously bonding the first or second layers to the polymer material. A method of making the composite integral sheet.

Abstract: A method and an apparatus for the production of a three-dimensional textile (3), wherein the textile (3) is formed from two sheets of textile (5, 6) placed face to face and connected together by a plurality of threads (10), impregnated with resin and inserted between two layers (16, 17) so as to form a layered structure (1). This layered structure (1) is inserted between two dies (25, 26) of a heated press which is subsequently closed to allow the resin impregnating the structure to distribute itself uniformly. The layers (16, 17) are then attached by vacuum to the faces of the dies (25, 26) which are then opened through a first controlled distance within the limit of the elastic recovery of the three-dimensional textile (3). The outermost layers of the structure (1) are then polymerized by heating the dies (24, 26) while the resin impregnating the threads (10) remains in a plastic state.

Abstract: A method and apparatus for forming a honeycomb structure in which a plurality of thermoplastic layers are fused together at selected locations. The thermoplastic layers at each of the selected locations are melted together to form a welded portion which includes first and second exterior surfaces. The welding of the thermoplastic layers is controlled so that no more than one of the exterior surfaces is melted. This partial melting of one layer prevents undesirable welding to adjacent layers. An apparatus for carrying out the method for welding thermoplastic honeycomb structures is also disclosed.

Abstract: The subject matter of this invention relates to a method of making glass fiber mat reinforcement material with a thermoplastic adhesive powder. Fiberglass strands are chopped and randomly air dropped onto a Teflon.RTM. coated conveyor belt to form a loose mat. A water mist is then applied to the loose mat and transport belt, before a powdered adhesive is dispensed. Heat is applied to plasticize the adhesive and finally the adhesive is solidified by cooling. The adhesive will then release from the transport belt and is adhered to the material forming the fiberglass reinforcement mat.

Abstract: A method of producing a sandwich plate that consists of a foamed core layer and two fiber-reinforced cover layers, comprising the steps ofproviding a sheet of a thermoplastic plastics material, such as polyetherimide, containing an amount of a suitable solvent or blowing agent;placing said sheet between two fiber-reinforced layers of a similar thermoplastic material, such as polyetherimide; placing the core web and cover layer assembly between two pressure plates;supplying heat and pressure to the pressure plates to cause foaming of the core web andcooling the pressure plates when a predetermined foam layer thickness is obtained.According to one aspect of the invention one of the cover layers has a remaining percentage of solvent that does not exceed 0.1% of weight.According to a second aspect of the invention the thermoplastic material in at least one of the cover layers is a modification having a higher chemical resistance than the thermoplastic material of the core layer.

Abstract: A method for producing a pultrusion product having a variable cross-section using a specially adapted temperature controllable pultrusion die includes the steps of pulling reinforcing fibers which have been impregnated with a heat curable thermosetting polymeric resin composition through a temperature controllable die, heating the temperature controllable die to a temperature sufficient to effect curing of the thermosetting resin, cooling the temperature controllable die to a temperature which is sufficiently low to prevent any significant curing of thermosetting resin passing through the pultrusion die, pulling the cured material and a predetermined length of uncured material from the die, reshaping the uncured material, and curing the reshaped material. The reshaping step can be used to provide off-sets, flanges, bosses and the like.

Abstract: An apparatus and method is disclosed for bonding a fiber reinforced plastic automotive body member to a reinforcement member. An adhesive is located between mating surfaces of the body member and the reinforcement member. Pressurized heated and cool air is used to heat and facilitate the cooling of the adhesive. The apparatus includes a switchable heating and cooling system that first provides pressurized heated air about outer surfaces of the body member and the reinforcement member, and thereafter, the system provides pressurized cool air about the same outer surfaces.