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 infusion. 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. Hollow tubes with moveable portions provide Channels which Assist in Resin Transfer Molding of composites (CARTM).

Abstract: The invention relates to molding a right cylindrical body from a settable loose granular composition in a mold cavity, in which a mold cavity (4) is fed with successive charges of the composition in the loose state and each new charge is thrust by means of thrust surfaces (11) into the surface S of the molded composition in order to cause the new charge and the molded composition to interpenetrate in such a manner as to densify the molded composition. The invention is applicable to making a pipe, in particular out of a cement composition.

Abstract: A method of manufacturing a molded article from a settable mixture includes the steps of in-taking a plurality of components into a plurality of separate material discharge containers sized relative to each other to provide the required mix ratio of the settable mixture. The components contained in the material discharge containers are discharged to a mold tool through a mixing head that receives each of the components separately and thoroughly mixes them into the settable mixture. The settable mixture flows from the mixing head to fill the mold tool. The mold tool rotates about an axis during the filling step to evacuate air from the mold tool. Pressure of the settable mixture is monitored during the filling step and rate of discharge of the settable component is varied in response to changes in pressure of the settable mixture.

Abstract: A method of forming a device including a plurality of micron or sub-micron sized features is provided. A master having a surface contour defining a plurality of features is provided. The surface contour of the master is coated with at least one layer of material to form a shell. The master is removed from the shell to form a negative image of the surface contour in the shell. The negative image in the shell is filled with material, for example, polycarbonate, polyacrylic, or polystyrene, to form a device having features substantially the same as the master. The negative image may be filled using injection molding, compression molding, embossing or any other compatible technique.

Abstract: A method of forming a unitary, composite structural member, and a member formed in accordance with the process. The process involves stitching a plurality of warp knit panel sections together to generally form a plurality of independent panel sections. The sections are placed within the dies of a molding tool such that a rib portion of each section aligns. Inflatable bladders are then slipped into voids formed in between the various panel sections of the assembly. The bladders are inflated to hold with one another. Resin is then infused into the panels that make up the assembly. The assembly is then cured. When the panels are removed from the molding tool a unitary, complexly shaped, composite structural member is formed.

Abstract: A process of making a microcontact printing stamp useful in the microcontact printing of a microcircuit. In this process an elastomeric microcontact printing stamp is formed by curing a degassed liquid elastomeric monomer or oligomer, optionally saturated with helium, a mixture of helium and an inert gas or a mixture of hydrogen and an inert gas, in a mold in which a photoresist master, defining a microcircuit in negative relief, is predisposed above a backplane.

Abstract: The vacuum insulator in accordance with the present invention comprises glass white wool body which density is 0.1˜0.5 g/cm3 in density and is below 0.0023 kcal/mh° C. in thermal conductivity, and a non permeable container surrounding the body in which the pressure is between 10?6 ˜10?1 torr. The vacuum insulator is fabricated by piling up glass white wool, thermal-pressutizing the piled glass white wool to form a body of 0.1˜0.5 g/cm3 in density wherein the pressurizing is done at 0.007˜1.5 kg/cm2 and under 20° C. for more than 10 minutes, putting the body in the non-permeable container, and producing a vacuum in the container.

Abstract: A mixture of carbon-containing fibers, such as mesophase or isotropic pitch fibers, a suitable matrix material, such as a milled pitch is compressed while resistively heating the mixture to form a carbonized composite material. Preferably, the carbonized material has a density of at least about 1.30 g/cm3. Preferably, the composite material is formed in less than ten minutes. This is a significantly shorter time than for conventional processes, which typically take several days and achieve a lower density material. A treating component may be impregnated into the composite. Consequently, carbon composite materials having final densities of about 1.6-1.8 g/cm3 or higher are readily achieved with one or two infiltration cycles using a pitch or other carbonaceous material to fill voids in the composite and rebaking.

Abstract: The inventive method concerns a process of transferring resin into reinforcing material used in the manufacture of composite articles. A first step in the method involves positioning at least one layer of the reinforcing material on the surface of an open mold. Subsequently, a sealant layer is applied in liquid form over the reinforcing material to create an airtight chamber encapsulating the reinforcing material between the sealant layer and the mold. After the sealant layer is allowed to cure, resin is drawn through the reinforcing material.

Abstract: A method and apparatus for curing composite materials that emit large volumes of volatiles during processing. The apparatus includes tooling having a rigid forming surface contoured to the shape of the formed composite part. A plurality of passages extend from the forming surface through the tooling. The passages are in fluid contact with an exhaust port. A composite workpiece is laid up and placed adjacent the forming surface. The apparatus includes a heater that heats the composite workpiece to temperatures at which volatiles are emitted. An evacuation system draws the volatiles away from the composite workpiece through the passages in the tooling and out of the exhaust port. One embodiment of tooling according to the invention is used to form a sine wave spar. The tooling includes upper and lower tool inserts upon which U-shaped composite channels are formed. The upper and lower tools are placed adjacent to each other to form the web of the spar.

Abstract: A process for forming a cushion layer of a preselected thickness on an inside of a prosthetic liner body is provided and includes the steps of introducing the liner body into a mold cavity; disposing a sufficient amount of cushioning material into the inside of the liner and directing a mandrel into the inside of the liner body. The driving action of the mandrel causes the cushioning material to be dispersed between the mandrel and the liner body, thereby forming the cushioning layer of preselected thickness.

Abstract: In a method for producing fiber-reinforced plastic components made of dry fiber composite preforms by an injection method for injecting matrix material, the arrangement of the fiber composite preform on one surface of the preform resulting in a flow promoting device, on a tool, creates a first space by a gas-permeable and matrix-material-impermeable membrane surrounding the preforms. Formation of a second space arranged between the first space and the surroundings by a foil, which is impermeable to gaseous material and matrix material, is provided, with removal by suction, of air from the second space resulting in matrix material being sucked from a reservoir into the evacuated first space and with the flow promoting device causing distribution of the matrix material above the surface of the preform facing the flow promoting device, thus causing the matrix material to penetrate the preform vertically.

Abstract: The invention provides a method for producing a foamed article comprising the steps of: heating a mixture comprising (a) 100 parts by weight of linear saturated polyester, (b) 0.1 to 10 parts by weight of a mixture as a coupling agent of 0 to 100% by weight of a compound having two epoxy groups in the molecule, and 100 to 0% by weight of a compound having two or more epoxy groups, and (c) 0.01 to 5 parts by weight of a metal salt of a carboxylic acid as a coupling reaction catalyst, at a temperature of a melting point of the polyester or more to provide a melt flow rate of 50 g/10 minutes or less and swell of 10 to 200%, whereby a polyester resin is formed; and heating and foaming the polyester resin using a foaming agent .

Abstract: A method of producing a foamed synthetic resin molding article by using a mold comprising a closed space formed by a lower mold and an upper mold as a cavity to be supplied with a material, closing the upper and lower molds, foaming the material, curing the foamed body and demolding the foamed and molded body, wherein the method comprises the steps of supplying the material for foamed synthetic resin molding article under atmospheric pressure, closing the upper and lower molds so that a gas in the mold can be exhausted, causing foam molding, preliminarily measuring a cavity fill-up time required for the foamed body of the material to fill up the cavity, thereafter supplying the material into the cavity under atmospheric pressure, closing the upper and lower molds so that the gas in the mold can be exhausted, causing foaming to proceed, and perfectly closing the upper and lower molds when the cavity fill-up time has passed.

Abstract: A method for removing volatile components from wet, polymer powders using a vacuum vented extruder is described. Polymer powders containing substantial amounts of water, 1-20% by weight, are rapidly converted to polymer compositions containing less than about 0.5% by weight water at high throughput rates while avoiding complications resulting from excessive steam backflow through the extruder feed throat. The method provides a screw design comprising a powder seal section upstream of kneading and melting sections of the extruder. Steam generated as the polymer is heated flows downstream to one or more vacuum vents for removal. The partially devolatilized polymer melt is then subjected to additional melt kneading and vacuum venting. The method converts wet polycarbonate powder containing residual methylene chloride to essentially dry polycarbonate powder containing less than about 1 ppm methylene chloride.

Abstract: When resins are injected into a cavity of an injection mold separably formed of a movable mold and an immovable mold to form a casting, a high-pressure gas is supplied into the cavity during a time period after completion of forming the casting till the injection mold opens partway, and the high-pressure gas is allowed to jet out through a clearance formed between joint surfaces of the movable and immovable molds while the injection mold is opening. More than one attraction gripper is used to hold, move and place an insert at a predetermined position in the injection mold. Magnetic shielding is provided between the injection mold and a magnet embedded at the predetermined position in the injection mold to restrict a leakage of a magnetic flux into the injection mold.

Abstract: A method and apparatus for filling preforms with resin or slurry includes a tank for holding the slurry and an autoclave for holding the preforms. The tank and autoclave have a common vacuum system connected thereto, and the tank is disposed above the autoclave. This arrangement provides a compact casting system which utilizes a vacuum and gravity to transfer slurry from the tank to the preforms within the autoclave.

Abstract: Method and device for producing elastane threads from spinning solutions using recycled elastane material.

Abstract: The invention relates to a process and an apparatus for simultaneously coating and forming a body (11), comprising the following steps:

Abstract: Cure and consolidation of a viscous thermoplastic resin, especially one that softens and melts at a high temperature, is improved by assisting autoclave pressurized momentum transport for compaction of the composite using high frequency, low amplitude acoustic vibration within the resin. The vibration induces shear thinning in the resin which promotes resin flow, achieves filling or collapse of voids, and assists consolidation of the composite preform.

Abstract: A process for producing a component from a sheet molding compound (SMC) material includes raw-material preparation, semi-finished product production and component shaping.

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: A method is disclosed for producing elastomer compounds for use in the production of rubbers. At least one elastomer to be processed for the production of an elastomer mixture can be slowly added to a mixer/extruder and is mixed and plasticized and/or masticated (melted) while it passes through the mixer/extruder. The elastomer, when slowly added to the mixer/extruder, can be present in a fluid medium in an evenly distributed form.

Abstract: An injection molding machine 10 utilizes a two part mold to produce a molded part. A machine includes a clamping mechanism 20 including one or more clamping cylinders 22 for applying a mold clamping force to the two part mold, an injection mechanism 30 for plasticizing material and injecting the plasticized material into the closed mold, and a controller 50 for powering the molding machine hydraulic system 52. In one embodiment, clamping pressure is automatically increased or decreased to allow air to escape as plasticized material flows into the mold cavity. In another embodiment, the controller provides a minimum clamp pressure to maintain the plasticized material within the mold as a function of fluid injection pressure to the screw member of the injection system.

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: 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 cup assembly having an open end, comprising: (a) a dual wall cup assembly comprising: (i) an outer cup having a truncated conical-like shape with side wall, larger top and smaller end, the end is closed and sealed by bottom wall and the top is open; (ii) an inner cup having a truncated conical-like shape with side wall, larger top and smaller end, the end is closed and sealed by bottom wall; and (iii) the inner cup is configured to be receivable within the outer cup to create a gap between side wall of an inner surface of the outer cup and an outer surface of the inner cup and between the bottom walls; (b) the cup assembly is a child spill-proof cup that has an upper end for removably mounting cap thereon, the cap is adapted to engage the upper end of the cup, the cap has a spout that projects from one side thereof upwardly, the spout is formed integrally with the cap and includes a front and rear walls that converge to an outwardly protruding tip of the spout; and (c) an overmold ring located on an outer p

Abstract: A composite crucible for pulling up monocrystalline silicon, which is superior in shape stability and suitable for a large-sized one is provided. The composite crucible is characterized in that a carbonaceous material as an outer layer and a quartz glass as an inner layer are integrally formed. Methods for preparing and regenerating a composite crucible are also disclosed.

Abstract: A system is proposed for encapsulating in plastics material leadframe items comprising an IC wired to a leadframe. Dust of the plastics material is removed from the encapsulation system, and in particular from those items where dust principally accumulates, such as the surfaces of the molds. To reduce the level of dust which enters the molding region, the path along which the leadframe items are conveyed to the molding region is closed at times when the leadframe items are not being transported there. Additionally, the leadframe items are conveyed to the molding region under a cover including a vacuum source, so that the dust is continually sucked away from them.

Abstract: A segmented tire mold having radially movable circumferentially spaced sliding center segments activated by sliding connections between an upper mold half and the segments in response to opening and closing of the mold.

Abstract: Vacuum assisted molding apparatus provides reliable sealing about the mold cavity while minimizing the area of the plant floor space occupied by the mold. The apparatus includes an upper die, a lower die, a vacuum source, and a sealing assembly. The upper die includes a generally horizontal molding surface and vertically extending sides. The lower die includes a generally horizontal molding surface cooperating with the upper die to form a mold cavity. The sealing assembly is operable to create a vacuum surrounding the mold cavity.

Abstract: A method for molding the fiber aggregate comprising placing divided members of a mold obtained by dividing the mold having gas permeability into the plurality of members in a developed state, filling cavities of the divided members of the mold in the developed state with the fiber aggregate wherein binder fibers having a lower melting point than that of crimped synthetic staple fibers are dispersed and mixed in matrix fibers composed of the crimped synthetic staple fibers, respectively, uniting the divided members of the mold in the developed state, uniting each divided and filled fiber aggregate, heating the united fiber aggregate, melting or softening the binder fibers, fusing the melted or softened binder fibers to the matrix fibers at their crossing points, then cooling and solidifying the melted or softened binder fibers and providing a molded product and an apparatus therefor.

Abstract: An exemplary method of manufacturing a polymer matrix composite electromagnetic shielding structure includes pretreating a dry fiber reinforcement with a composition including a carrier and a conductive element, laying out the pretreated reinforcement to form a pre-form structure, applying a resin to the pre-form structure, and curing the resin at room temperature. Another exemplary method of manufacturing a polymer matrix composite electromagnetic shielding structure includes laying out a plurality of dry fiber reinforcements, placing at least one ply between any two of the plurality of dry fiber reinforcements, the ply having a non-woven including a conductive material, applying a resin to the plurality of dry fiber reinforcements and the at least one ply, and curing the resin.

Abstract: An improved method for embossing expanded graphite sheet material including removing at least a portion of the gas from within the material by exposing the material to a pressure less than atmospheric pressure, and then embossing the material.

Abstract: An article and method of preparing a synthetic solid surface material having a simulated burled wood effect in a pattern formed by preparing a resin matrix with iron oxide pigments and pearlescent mica pigments, adding a darker mica pearlescent pigment and/or an iron oxide pigment composition with a slightly less specific gravity than the matrix for the creation of a burling effect, pouring into a flat substrate in paths, and applying vibration or agitation which generally allows or speeds the darker pigment to rise and bubble to create a burling effect on the back side of the solid surface. The back side of the slab, the surface generally not in contact with the mold, is then sanded to the desired thickness on a wide belt sander.

Abstract: The invention relates to a process for the production of marble conglomerate slabs, starting from marble sand and/or granulates, additivated with binders, of the kind comprising a step of mixing the raw materials, a step of placing the mixture on a conveyor belt or on moulds, an under vacuum vibro-compaction step and a following step of polymerisation of the binder, further comprising a step of placing a protective sheet on said conveyor belt or on the base of said moulds, before pouring the mixture, and on said mixture, said protective sheet being comprised of hydrosoluble plastic material in such a way to coat the mixture above and at the bottom before the vibro-compaction step, said hydrosoluble material sheet beeing automatically removed, after the binder polymerisation step, from the water of the slab finishing workings.

Abstract: A fiber-reinforced, polymeric implant material useful for tissue engineering, and method of making same are provided. The fibers are preferably aligned predominantly parallel to each other, but may also be aligned in a single plane. The implant material comprises a polymeric matrix, preferably a biodegradable matrix, having fibers substantially uniformly distributed therein. In preferred embodiments, porous tissue scaffolds are provided which facilitate regeneration of load-bearing tissues such as articular cartilage and bone. Non-porous fiber-reinforced implant materials are also provided herein useful as permanent implants for load-bearing sites.

Abstract: A method for manufacturing a polyethylene terephthalate (PET) packaging web, wherein PET material is extruded using a twin-screw extruder and wherein the extruder interior space is degassed during the extrusion. The molten plastic is outputted in a strip shape from a spinning head located after the twin-screw extruder. The plastic strip is then cooled and stretched.

Abstract: A profile-extruded article is disclosed, made of a fiber-reinforced polymer of vinyl-chloride monomer, wherein the article has a ratio of actual specific gravity to theoretical specific gravity of nearly unity. A method of making the article is also disclosed.

Abstract: There is disclosed a process for removing volatile components in a polyarylene sulfide resin which is produced by subjecting a sulfur source and a dihalogenated aromatic compound to polymerization reaction in an aprotic organic solvent, comprising using an extruder which is equipped with front vent having an opening length in the range of 4D to 11D (D: screw diameter) and which has a distance between a terminal position of a screw in a kneading portion and the opening portion of the front vent being in the range of 4D to 15D. The process is capable of steadily and economically removing volatile components in the polyarylene sulfide resin without necessitating expensive machinery or equipment such as a dryer without plugging up the opening portion of a vent even in the case of degassing a PAS resin having a low molecular weight and further, thus enabling a long-term continuous stable running.

Abstract: A programmed material consolidation apparatus includes at least one fabrication site and a material consolidation system associated with the at least one fabrication site. The at least one fabrication site may be configured to receive one or more fabrication substrates, such as semiconductor substrates. A machine vision system with a translatable or locationally fixed camera may be associated with the at least one fabrication site and the material consolidation system. A cleaning component may also be associated with the at least one fabrication site. The cleaning component may share one or more elements with the at least one fabrication site, or may be separate therefrom. The programmed material consolidation apparatus may also include a substrate handling system, which places fabrication substrates at appropriate locations of the programmed material consolidation apparatus.

Abstract: Molds made from a porous metal material allow for superior injection and compression molding of golf ball portions, such as cores, intermediate layers and covers. Use of the porous material in the sections contacting molding material, such as mold sections forming cavities, pins, or runners, allows for production of superior ball portions, with reduced formation of pin marks, knit lines, and other imperfections leading to degradation of the properties of the resulting portions. All or part of the mold can be made from the porous metal. Particular mold apparatus incorporate vacuum and/or compression devices to improve venting and release of the ball portions from the mold. Also, methods for preparing a layer for a golf ball incorporates using a mold made from a porous material and incorporating use of vacuum or pressurizing devices.

Abstract: The method of producing slabs made of granulated stone and/or sand bound with a hardenable resin by compaction under vacuum and subsequent hardening in which before the vibratory compaction the mixture is spread to a uniform thickness on a support, the support being protected by highly resilient sheet material. A lower sheet material has a shaped configuration comprising a flat base and a peripheral frame projecting from the flat base for a predetermined height so as to define a seat of dimension corresponding in plan to those of the slab to be produced. The peripheral frame having a height which is lower by a predetermined amount than that of the final slab produced.

Abstract: A method and system of forming a fire door core. Hydraulic binder and resin are supplied from raw material bins and mixed to provide a submixture. Exfoliated vermiculite is then mixed with the submixture to provide a mixture that is deposited into a plurality of compression molds. Each of the filled molds are pressed in a press at a predetermined temperature at a predetermined pressure for a predetermined period of time sufficient to harden the mixture into a hardened slab. The hardened slabs are then removed from the molds, impregnated with water or steam in a water impregnation assembly and dried in a drying assembly.

Abstract: A process of making a microcontact printing stamp useful in the microcontact printing of a microcircuit. In this process an elastomeric microcontact printing stamp is formed by curing a degassed liquid elastomeric monomer or oligomer, optionally saturated with helium, a mixture of helium and an inert gas or a mixture of hydrogen and an inert gas, in a mold in which a photoresist master, defining a microcircuit in negative relief, is predisposed above a backplane.

Abstract: In the method of resin molding of the present invention, air can be perfectly discharged from a specific area of a molding die including cavities, resin paths, pots, etc. so as to mold high quality products. The method comprises the steps of: covering a specific area of a molding die, in which air is left, with release film; clamping a work piece and the release film between an upper die and a lower die of the molding die so as to air-tightly seal the specific area; discharging the air from the sealed specific area; and filling a molding section with resin.

Abstract: A method of transfer molding, wherein a top-half mold and a bottom-half mold of an apparatus form a plurality of cavities interconnected, and wherein a pressure adjuster reduces the pressure of the cavities every time a specified amount of resin is supplied into any one of a plurality of cavities.

Abstract: The present invention relates to a method for manufacturing a large FRP member and has the following structure.

Abstract: A method of forming graphitic bodies comprises the steps of:—

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.