Abstract: A composite structure having first and second layers which are wrapped about one another to form a cylinder. The first layer is formed from an expandable film or foaming adhesive. The second layer is formed from a reinforcing member. The second layer is overlaid onto the first layer. The first and second layers are then rolled together in a jelly roll fashion. The roll is then cured to expand the film. The structure may thereafter be incorporated into a panel and drilled to receive a fastener. The composite structure is generally lightweight having a high compressive strength-to-density ratio. The physical properties of the composite structure may be tailored to a particular application. For example, the physical properties of the composite structure may be tailored to provide improved energy absorption or a reduced initial peak compressive strength. A method for forming a composite structure from an expandable film member and a reinforcing member is also provided.

Abstract: A method and apparatus for producing a composite component having a variable thickness includes placing a caul member over a plurality of laid-up prepreg plies supported by a mold and curing the lay-up in an autoclave. The mold includes a cavity for receiving the lay-up that is defined by a bottom surface, a plurality of walls extending upwardly from the bottom surface, and an open upper face surrounded by a mold edge. A support flange extends inwardly toward the center of the cavity from each of the walls at a predetermined distance upward from the bottom surface. The predetermined distance varies along the length of the mold and generally conforms to the outer profile of the composite component to be fabricated. The caul is positioned over the lay-up and defines a longitudinal axis extending along the length of the caul and a lateral axis extending along the width of the caul.

Abstract: Structural members for doors and the like can be manufactured from plastic foamed composites containing wood flour by the steps of (1) dry mixing a blend of powders including PVC powder, wood flour, powdered thermal stabilizers, powdered foaming agent and a powdered gelatinization agent, (2) adding the mixed powder to a thermal stirring mixer to obtain a homogeneous dispersion of the several powders (3) transferring the homogeneous dispersion of powders to a cold stirring mixer and stirring at speeds sufficient to avoid agglomeration of the homogeneous dispersion of the several powders and (4) placing the non-agglomerated homogeneous dispersion of the several powders in a feeding hopper of an extrusion machine and extruding shapes for the desired components. The vacuum venting of the extrusion machine can be controlled to achieve components with more desirable surface features. Lubricants can be added to the homogeneous dispersions of the several powders to aid in the extrusion process.

Abstract: There is provided a manufacturing method of an optical device having a micro-asperity pattern that has various kinds of accurate three-dimensional shapes and is realized as thin films. A substrate is coated with a resin thin film made of a photosensitive resin, and the temperature of the resin thin film is controlled so as to be lower than the photosensitivity extinction temperature of the resin thin film. A micro-asperity pattern of a stamper is pressed against the resin thin film when the resin thin film is in a softened or melted state by pressurizing means, whereby a micro-asperity pattern is formed on the surface of the resin thin film.

Abstract: An automobile interior component that includes a honeycomb structure is disclosed. A honeycomb defining structure is formed in one of the mold halves of a mold that is used to manufacture the automobile interior component. The honeycomb defining structure partially defining the article-defining cavity in the closed position of the mold. The honeycomb defining structure comprises a plurality of generally cylindrical recessed areas defined in a portion of said one of said first and second mold halves, and a post member that is disposed in each one of the recessed areas. The introduction of a moldable material into the article defining cavity during the molding process causes the moldable material to flow into the honeycomb defining structure and, therefore, integrally form a desired honeycomb structure as a portion of the automobile interior component during the molding process.

Abstract: A new and improved method and apparatus for liquid resin molding, using subsurface venting is described herein. The inserts can be placed virtually any where in the mold, and vacuum or injection can be introduced to suit the part geometry. The process is to draw the resin through the mold, thereby creating a uniform wetting effect of the fabric by the resin.

Abstract: The present invention provides a method and apparatus for dispensing materials onto a substrate. In one embodiment, a dispensing system includes a controller, a vacuum source in electrical communication with the controller, the vacuum source applying a vacuum to at least a portion of the substrate in response to an instruction from the controller, an injector in electrical communication with the controller, the injector comprising a valve in communication with a pressure source and a material port in communication with a material source, the valve permitting material from the material source to be dispensed onto a substrate in accordance with an instruction from the controller. In one embodiment, the dispensing system also includes a trap in communication with the vacuum source, where the trap substantially prevents excessive material dispensed by the injector from contacting the vacuum source.

Abstract: Disclosed is a mandrel structure for extruding a tube composed of a non derivatized cellulose. The mandrel includes a hollow sizing portion having openings which gather gas bubbles that may evolve at the interface between the extruded tube and the sizing portion and allows the gas to pass into the hollow interior of the mandrel.

Abstract: A resin sealing method for sealing a gap between a substrate and a semiconductor chip mounted thereon includes the following steps: applying a predetermined amount of resin at and along the circumference of the semiconductor chip in such a manner so as to maintain a space between the resin and a side face of the semiconductor chip; reducing the pressure of the atmosphere around the substrate to exhaust air from the gap; reducing the viscosity of the applied resin to partially fill the gap with resin, thereby leaving a closed cavity reduced in pressure; pressurizing the atmosphere around the substrate to compress the closed cavity due to the pressure difference from the surrounding atmosphere to entirely fill the gap with resin. The exhausting of the air is very stable, and a concentration of resin at the corner of the semiconductor chip can be suppressed, thereby avoiding the spattering of resin onto the top of the chip.

Abstract: A method for forming a three dimensional polymeric structure includes providing at least one paint layer and providing a bonding layer coupled to the at least one paint layer to form an insert having a bonding surface provided by the bonding layer. A mold having a hollow interior bounded by an interior surface is further provided. The insert is positioned within the interior along a portion of the interior surface. At least one charge of thermoplastic material is deposited into the interior. The interior is heated while the mold is rotated and rocked. As a result, the thermoplastic material melts and is deposited against the interior surface of the mold and against the bonding surface of the insert to form a three dimensional structure within the interior. The three dimensional structure is then removed from the interior of the mold.

Abstract: Polyethyleneterephthalate extrusion equipment of material in granule form, still humid, coming from both ground recovered products and also virgin material, comprising a chassis (29), containing a co-rotating, oil-thermoregulated extruder with two screws (31, 32), which comprises a first zone (A), equipped with an opening (34) where there is an aspiration hood (35) for a first “open top” degassing, a second zone (C) where there is at least one stack (37, 38) for a further degassing, between the two zones (A, C), there being a tight zone (B), and a carrying and loading zone (E) activated by the screws (31, 32).

Abstract: A high throughput, automated process for coating ceramic monoliths used as catalytic converters that overcomes problems with coating monoliths individually in a mold. The monoliths are provided with end caps to cover the open functional ends, then loaded serially into an inlet channel leading to an extrusion chamber. As each monolith is pushed into the channel, one monolith enters the extrusion chamber, and the monolith just coated in the extrusion chamber is made to exit onto a finished part conveyor. Thereafter, the end caps are removed and cleaned for reuse on new monoliths yet to be coated.

Abstract: A preform having a small content of acetaldehyde can be advantageously produced by forming a vent, from which air is exhausted during molding, at a specific position of a molding machine in order for an aromatic polyester to be advantageously exposed under reduced pressure in a molten state when a preform of the aromatic polyester is injection molded.

Abstract: A method of preparing filled, modified and fiber reinforced thermoplastics is distinguished by the fact that polymer as matrix material together with blend polymer is fed to a twin screw extruder in a single manufacturing process, filler being supplied through a feeder device after the melting. Then fiber rovings are fed in and cut into long fiber sections in a fiber incorporation zone.

Abstract: A composite material for vehicle hulls and a hull molding process comprising a gel coat, a skin coat, a bulk fiberglass layer and adhesive applied to a top mating surface and a bottom mating surface within a top mold and a bottom mold, wherein the adhesive forms a connector. The two molds are placed together, and after the adhesive sets, foam is introduced into at least one cavity formed when the molds are brought together. The molds remain closed while the foam is introduced.

Abstract: An improvement in a process of making honeycomb articles, which process utilizes a co-rotating, intermeshing twin screw extrusion apparatus to mix, screen, and extrude a batch of ceramic materials through a die, the improvement which comprises the steps of separating the mixing and screening phase from the extrusion phase, by passing the batch through a first co-rotating, intermeshing twin screw extruder or a mixer extruder to mix and screen the batch, and then directly passing the mixed and screened batch through a second co-rotating, intermeshing twin screw extruder or a pumping extruder to extrude said batch through a die assembly to produce a honeycomb article.

Abstract: A molding die apparatus and a method thereof are provided, which ensures for air and gas (or fluid) present in a resin filling space to be exhausted so as to be able to fill molten resin into the cavity smoothly and uniformly thereby enabling production of a high quality molded resin product suitable as an optical disc substrate or the like having optimum optical properties required therefor. The molding die apparatus for obtaining the molded product by injecting the molten resin into a cavity that is formed between dies includes a vacuum apparatus which is disposed in proximity to the cavity, the vacuum apparatus including a vacuum tank, an exhaustion channel and a vacuum valve which controls open and close of a channel between the vacuum tank and the exhaustion channel, and the cavity is exhausted efficiently and rapidly by the vacuum apparatus.

Abstract: A polyester resin is thickened in a chamber 4 by first introducing the feed resin through a port 2 and dehydrating in a drying section 14 under reduced pressure. A chemical agent is then added to the dehydrated feed resin and mixed therewith in a thickening section 15. The mixing occurs while deaerating under reduced pressure. The chemical agent functions to either increase the viscosity of the feed resin or suppress the lowering thereof.

Abstract: A process for making a shaped product from thermoplastic polycarbonate is disclosed. The process comprises producing polycarbonate melt by a method selected from the group consisting of phase interface and melt transesterification and introducing the melt directly into a forming apparatus to form a shaped product. The forming apparatus is selected from the group consisting of an injection molding machine and an extruder. The process is characterized in the absence therefrom of polycarbonate in granular form.

Abstract: The present invention relates to methods and apparatus of molding composite parts by liquid resin infusion. The invention involves the creation of temporary resin distribution channels on the surface of a preform to aid in the distribution of resin during infiltration. In general, these methods are improvements over the art because the molds are cheaper to make, the parts produced are of higher quality, minimal waste is produced and the time to infiltrate the preform is reduced.

Abstract: A mixture is formed that comprises at least some to about 10 wt % boron nitride and silicon. A body comprising a component that is wetted by or reacts with silicon is contacted with the mixture and the contacted body is infiltrated with silicon from the mixture.

Abstract: A mold apparatus and method is used to form a solid injection molded plastic part having no internal voids, a Class A finish, a sink-free exterior appearance surface, and unevenly distributed structural detail extending from the opposite surface, the detail including free-standing reinforcement ribs, attachment bosses, and the like. In sequence, a seal groove in the mold cavity is reduced to a pressure below atmospheric (i.e., negative), a charge of hot thermoplastic is introduced into the mold cavity and seal groove whereby to form a gas seal ring, and pressurized gas is injected into the mold cavity. The pressurized gas forces the hot plastic from one mold half against the other mold half, and the gas seal formed by the plastic prevents gas on one side of the thermoplastic from reaching the appearance surface of the part.

Abstract: A process for producing molded pitch based foam is disclosed which minimizes cracking. The process includes forming a viscous pitch foam in a container, and then transferring the viscous pitch foam from the container into a mold. The viscous pitch foam in the mold is hardened to provide a carbon foam having a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts.

Abstract: A novel fiber-reinforced composite member having at least one projection is formed by (a) disposing a preform made of a fiber-reinforced composite material on a forming plate; (b) placing a shape-retention means composed of a plurality of soft unit members adjacent to each projection of the preform; (c) completely covering the preform and the shape-retention means with a bagging film having a sealant attached to the periphery; (d) adhering the sealant to the forming plate such that the preform and the shape-retention means are completely sealed by the bagging film; (e) evacuating the inside of the bagging film; and (f) heating the preform under pressure to form a fiber-reinforced composite member.

Abstract: High levels of inorganic filler, processing fluid and silicone polymer are compounded and devolatilized into homogeneous filled compositions with requisite reinforcing properties and levels of volatiles. In the method, a filler, processing fluid and silicone polymer are mixed in a first compounding apparatus to produce a dispersed composition containing volatiles. The dispersed composition is then compounded in a long extruder having an L/D ratio of greater than 50 to devolatilize the dispersed composition.

Abstract: In a method for molding a raw material including a plastic material or a mixture of plastic and non-plastic materials fed into a cylinder, the said raw material is subjected to a melt-kneading performed under oxygen-free conditions, and at the same time the molten material is sent from the tip of an extrusion screw towards the head section of the cylinder in straight flow conditions. In the method satisfactory molding can be made for plastics of poor fluidity or thermal stability or for plastic materials mixed with more than 10 to 30% by weight of wood flour, paper powders, stone powders, metal powders, fiber reinforcements and the like, without causing molding defects such as burn or cavitation; and also for raw materials mixed with more than several per cent by weight of metal powders or stone powders without causing excessive wear at the extrusion screw.

Abstract: A process for injecting a urethane material into a mold cavity from a gate to mold articles. Urethane molded articles are produced by first forming a coating film layer on the inside surface of a mold cavity. Next, a first urethane material containing pigment is injected into the cavity. Finally, a second urethane material containing more pigment than the first urethane material is injected into the cavity.

Abstract: A method for recovering VOC and HAP emissions in the production of a lignocellulosic product is provided. The method comprises forming a mat of lignocellulosic material by bonding together and mat in a product formation press with an adhesive material to produce the lignocellulosic product. VOC and HAP emissions are produced during the formation of the lignocellulosic product in a product formation press. The VOC and HAP emissions produced are withdrawn during the formation of and lignocellulosic product prior to removal of the lignocellulosic product from the product formation press. Then, the VOC and HAP emissions which are withdrawn from the formation press are recovered without releasing same to the atmosphere. The product formation press is substantially closed to the surrounding atmosphere.

Abstract: The device and method of the invention utilizes a vacuum pump, a casting device, first and second CIR Connectors, a connector cuff, a casting balloon, a heating chamber or oven, a supracondylar wedge, and a CIR alignment/vacuum forming jig to create a prosthetic device under field conditions.

Abstract: A process and device are disclosed for manufacturing foam moldings. The parting plane of the mold has a circumferential vacuum channel, the top mold half has a suction channel for quickly evacuating the mold and self-closing expansion channels are arranged at the highest points of the inner cavity of the mold.

Abstract: For the production of a particularly dimensionally stable cable set, the single conductors(22) of the cable set are initially inserted into a cavity (8) of a foam tool (2) and a foaming material is subsequently filled in. To dispense with involved and expensive hydraulic equipment, a vacuum is generated to press a top half (6) and a bottom half (4) of the foaming tool (2) against each other. For this, vacuum channels (6) are preferably provided, which extend along sides of the cavity (8).

Abstract: A method for the production of molded bodies comprising foam particles is proposed in which the foam particles are shaped and welded together using microwave energy. The foam particles are accommodated in a foil-like bag and the bag is manually shaped or shaped through the use of a shaped mold with simultaneous change of the shape of the foam particles, and evacuated into a dense package. Microwave energy is subsequently used to melt together at least the surfaces of the foam particles. The method in accordance with the invention is particularly well suited as an economical manufacturing technique for packaging, in particular specialized packaging for models, small production runs, prototypes and the like.

Abstract: A method and apparatus for preparing single layer tiles or slabs from a mixture of a granulated stone material having a selected particle size, and from a slurry formed by cement, a quantity of between 0.25 and 0.36 parts by weight of water relative to the weight of cement, and a plasticizer for cementitious slurries, in which the quantity of slurry added is slightly in excess of the quantity corresponding to the void fraction of the granulated material, in forming mould, containing a layer of predetermined thickness of the mixture, to be subjected to a first very short deaeration step under the effect of a very high vacuum and to a subsequent vibration step under a lower vacuum, after which the mould goes on to seeing and hardness steps.

Abstract: A method of constructing large, unitary, fiber-reinforced Polymer composite containers using a vacuum assisted resin transfer molding process. The method allows for the construction of container systems with only two separately molded parts—an open box consisting of a base (i.e., floor), 2 sidewalls and 2 endwalls, and a cover (i.e., roof). The method results in a structure which maintains the continuity of the reinforcement fibers across the junction between the floor, side, and end walls corners. This method can be applied to very large composite structures such as railcar bodies, intermodal containers, and shelters.

Abstract: Polyurethane molded articles are produced from a flowable polyolpolyisocyanate reaction mixture on a shot-wise basis. The flowable reaction mixture is formed by combining the components of that mixture in the mixing chamber of a mixhead. The contents of the mixhead are introduced (preferably via an outlet pipe) into a mold in a manner such that the mixing chamber is substantially emptied in each case. Any ambient gas in the mixing chamber is then removed before the respective next shot is initiated.

Abstract: Composite fibers useful for preparing diaphragms are prepared by (a) mixing a PTFE or PTFE copolymer dispersion or powder with a finely divided inorganic material and a fiber forming material, (b) shear heating the resulting mixture to a temperature at which sheared to PTFE or PTFE copolymer becomes flowable without showing signs of decomposition while removing the dispersion medium, if a PTFE or PTFE copolymer dispersion is used, (c) cooling the mixture to below 70° C., (d) mix shearing the mixture at below 70° C. to form composite fibers.

Abstract: A low pressure dryer for granular or powdery material includes a plurality of canisters rotatable about a common vertical axis serially among material heating, vacuum drying and material inventory discharge positions; pneumatic piston-cylinder means for rotating the canisters about said axis among said heating, vacuum drying and inventory discharge positions; means for heating contents of a canister at said heating position; means for sealing and drawing vacuum within a canister at said vacuum drying position and means for selectably permitting downward flow of dried granular or powdery material out of a canister at said discharge position where said canisters move collectively and unitarily one with another.

Abstract: In order to provide a process for the production of a component consisting of a fiber reinforced material, with which liquid resin is supplied to a semifinished fiber article by way of application by vacuum pressure, it is provided for a heat curing resin to be used as resin and for application by vacuum pressure and temperature to be controlled such that in relation to the liquid resin the boiling point curve of the resin is not exceeded.

Abstract: According to this invention, there is provided a molding method and apparatus which increase the gas permeation speed in obtaining a foamed resin molded product by letting a gas permeate a molten resin material.

Abstract: A method for molding composite structural plastic components is disclosed wherein such components are cast from a polymerizable thermoset or thermoplastic composition in a conventional metalcasting mold. In the instant invention, a low viscosity thermoset or thermoplastic composition having reinforcing fibers distributed therein is poured into conventional metalcasting molds, obviating the need for high heats and pressures associated with injection or compression molding of composite materials as taught in the prior art. In the case of a thermoset resin, the object to be fabricated is fully cured by the action of a catalyst at relatively low exothermic resin temperatures. In the case of a thermoplastic resin, curing is generally achieved independently of high added heat and pressure. If using a thermoplastic such as nylon 6 in the present invention, a preferred method of use involves the addition and combination of fiber reinforcements while the nylon 6 resin is being manufactured.

Abstract: In a first aspect, a process for forming deodorant or antiperspirant sticks by continuously forming a mobile composition for dispensing into containers or molds at a rate matched with the rate at which it is dispensed, and in other aspects a process in which a mobile deodorant or antiperspirant composition is dispensed by injection molding, i.e. a process in which the deodorant or antiperspirant composition is dispensed under pressure. The composition at the time of injection moulding is preferably either in the vicinity of its regular set temperature, particularly in the range of about 0-3° C. below the regular set temperature and/or partially structured at the time of its delivery it into a container or mold.

Abstract: A method for continuously producing expanded thermoformable materials comprising the steps of: conveying a thermoformable assembly by means of a conveyor through a plurality of heating zones, whereby the thermoformable assembly is heated to a temperature at which the thermoformable material adhesively bonds to the first and second mold plates; disposing the thermoformable assembly between an upper press plate and a lower press plate, and heating the thermoformable material to a temperature in the range between about 50° to 300°C. while moving the upper and lower press plates so as to effect an expansion of the cross-section of the thermoformable material; and conveying the expanded thermoformable material through a cooling zone, wherein the expanded thermoformable material is cooled to a temperature sufficient for maintaining its structural integrity.

Abstract: A process for the preparation of a powder coating composition, wherein 5-90% by weight of at least one monomeric compound selected from glycidyl group-containing unsaturated compounds and methylglycidyl group-containing unsaturated compounds is copolymerized with 95-10% by weight of an ethylenically unsaturated monomer in methanol to obtain a resin solution. The resin solution is spray-dried to obtain a powdery resin. Alternatively, the resin solution is fed to an extruder having a die and a plurality of vent ports and extruded through the die, while removing volatile matters through the vent ports, to obtain extrudates. The extrudates are pulverized to obtain a powdery resin.

Abstract: A multi-chamber vacuum encapsulation system for encapsulation of semiconductor chip packages. The encapsulation system includes a dispense chamber, an inlet chamber mounted adjacent an inlet end of the dispense chamber, and an outlet chamber mounted adjacent an outlet end of the dispense chamber. The dispense chamber includes a material dispensing head for dispensing encapsulant material about the peripheral edges of chip packages under at least partial vacuum of the dispense chamber. A transport mechanism is provided in the dispense chamber for moving the chip packages between the inlet and outlet ends of the chamber. During the encapsulation process, the dispense chamber remains evacuated at all times while the smaller inlet and outlet chambers are evacuated and vented in a controlled manner to allow transfer of chip packages to and from the dispense chamber without venting of the dispense chamber to atmosphere.

Abstract: A transducer backing material includes a sticky epoxy resin containing tungsten particles and silver particles. A method of applying a backing material to a transducer includes pouring a mixture of epoxy resin, tungsten particles, and silver particles into a mold containing a layer of piezoelectric material, degassing the mixture, and curing the mixture at a pressure of approximately one atmosphere until the mixture dries.

Abstract: A process for the preparation of a powder coating composition, wherein 5-90% by weight of at least one monomeric compound selected from glycidyl group-containing unsaturated compounds and methylglycidyl group-containing unsaturated compounds is copolymerized with 95-10% by weight of an ethylenically unsaturated monomer in methanol to obtain a resin solution. The resin solution is spray-dried to obtain a powdery resin. Alternatively, the resin solution is fed to an extruder having a die and a plurality of vent ports and extruded through the die, while removing volatile matters through the vent ports, to obtain extrudates. The extrudates are pulverized to obtain a powdery resin.

Abstract: A system for making extruded cement-based articles. The process can include forming a cement-based feed mixture including water, aggregate and binder and directing the feed mixture to a vacuum zone, wherein sufficient vacuum is maintained in the vacuum zone to remove entrained air and, preferably, excess water, from the feed mixture. The feed mixture is held in the vacuum zone at a negative pressure for a time sufficient to form a vacuum-treated or densified mixture. The vacuum-treated or densified mixture is passed through an extruder at an elevated pressure to provide an extruded cement-based article.

Abstract: A method of a fabricating silica glass by sol-gel process is provided. The method includes mixing silica, a binder, a dispersing agent and a gelling agent, and forming a sol without air bubbles; injecting the sol into a mold, the injection of the sol into the mold being controlled by the pressure of an inert gas; gelating the sol injected into the mold and demolding the gel; and drying the demolded gel, and thermally-treating the dried gel. Therefore, incorporation of impurities and air bubbles during injection of a sol into a mold is minimized, and injection amount and injection rate of the sol can be controlled.

Abstract: A plastic molding for use in an optical device, a method of producing the molding by injection molding, and an apparatus for practicing the method are disclosed. Only a part of a molding expected to sink is surely caused to sink while, e.g., a mirror surface is surely transferred to a desired part of the molding.

Abstract: A system and method of forming a carbon fiber composite material in which a series of carbon fibers are woven together and treated with a resin to form a sample or weave. The carbon fiber sample is then vacuumed, compressed and is cured to form a solid plank or board that is then cut, sanded and polished to form a finished product.