Impregnation Of Batt, Sheet, Or Filament Patents (Class 264/136)
  • Patent number: 11410012
    Abstract: A method, apparatus, and product-by-process, for preparing an RFID access card constructed out of wood is disclosed. The method involved preparing two wooden surfaces of appropriate thickness, preparing an RFID chip emitting an appropriate frequency, and pressing the wooden surfaces and the RFID chip together through the use of adhesive(s) and a hot press and a cold press. The apparatus included an RFID access card constructed out of at least two wooden surfaces where an RFID chip is disposed between the two surfaces. The two wooden surfaces are attached with a hot melt adhesive.
    Type: Grant
    Filed: July 30, 2020
    Date of Patent: August 9, 2022
    Assignee: Global Card Systems Company Ltd.
    Inventor: Xinwen Ye
  • Patent number: 11236019
    Abstract: A composite material and process for forming composite material. The composite material comprises a quantity of plastinated plant distributed within a matrix material. The process comprises separating a plant material into plant fibers plastinating the plant fibers and combining the plastinated plant fibers with a matrix material. The plant fibers may be selected form the group consisting of bamboo, hemp and flax. The plant fibers may be formed by crushing a portion of a plant. The matrix material may comprise Polyethylene Terephthalate (PET). The PET may be shredded and heated. The heated composite material may be formed into rebar and be arranged in a pattern within a concrete slurry.
    Type: Grant
    Filed: October 29, 2018
    Date of Patent: February 1, 2022
    Assignee: NetZero Enterprises Inc.
    Inventors: Grant Raymond Bogyo, Ronald Fredrick Ryde
  • Patent number: 11230084
    Abstract: A method of making a hybrid composite component, the method including interleaving one or more metallic mesh laminae with two or more interleaved laminae of a first fiber reinforced composite material, wherein at least a first portion of the one or more metallic mesh laminae extends past a first edge of the two or more interleaved laminae of the first fiber reinforced composite material, and wherein at least a second portion of the two or more interleaved laminae of the first fiber reinforced composite material extends past a second edge of the one or more metallic mesh laminae; and providing one or more abutting laminae of a second fiber reinforced composite material in a position abutting the second edge of the one or more metallic mesh laminae, wherein the one or more abutting laminae of the second fiber reinforced composite material are interleaved with the second portion of the two or more interleaved laminae of the first fiber reinforced composite material.
    Type: Grant
    Filed: June 25, 2019
    Date of Patent: January 25, 2022
    Assignee: HONDA MOTOR CO., LTD.
    Inventor: Ryan M. Hahnlen
  • Patent number: 11231008
    Abstract: A pultruded fibrous composite strip, a spar cap made from such strips, a wind turbine rotor blade having such a spar cap and a method for making a spar cap from such strips are provided. The strip is stacked with similar strips to form the spar cap. The strip has a substantially constant cross-section defined by first and second mutually opposed and longitudinally extending sides, and by first and second longitudinal edges. The first and the second sides include first and second abutment surfaces, respectively. The first and/or the second abutment surfaces has corrugated profile such that a plurality of longitudinally extending grooves are defined on the abutment surface having the corrugated profile. When the strip is stacked with similar strips, and subsequently resin is infused, the grooves on the abutment surface having the corrugated profile facilitate transfer and flow of the resin into spaces between the stacked strips.
    Type: Grant
    Filed: December 13, 2018
    Date of Patent: January 25, 2022
    Assignee: SIEMENS GAMESA RENEWABLE ENERGY A/S
    Inventors: Donato Girolamo, Jens Jørgen Østergaard Kristensen, Michael Noerlem
  • Patent number: 11230777
    Abstract: A method of forming a wear-resistant coating on an article includes depositing a chromium coating on a substrate of the article, and subsequently heating the coated article to enhance a plurality of through-cracks within the chromium coating. The method further includes applying a liquid filler material to the coated article such that at least one of the plurality of through-cracks is at least partially occupied by the filler material, and solidifying the liquid filler material.
    Type: Grant
    Filed: June 20, 2019
    Date of Patent: January 25, 2022
    Assignee: Hamilton Sundstrand Corporation
    Inventors: Blair A. Smith, Claude J. Moreau
  • Patent number: 11187204
    Abstract: Provided is a method for fabrication of a profile for a spar cap for a wind turbine blade, wherein the profile is fabricated in a pultruding process using one or more strands and/or layers of unidirectional fibres or rovings of unidirectional fibres arranged along a longitudinal direction of the profile and a tool for moulding of the fibres, wherein one or more additional fibres or rovings of additional fibres are introduced in the pultruding process prior to the moulding, wherein the additional fibres are arranged under an angle to the unidirectional fibres, and/or wherein one or more surficial fibres or rovings of surficial fibres are introduced in the pultruding process after the moulding, wherein the surficial fibres are arranged on the outer surface of the moulded profile.
    Type: Grant
    Filed: January 14, 2019
    Date of Patent: November 30, 2021
    Assignee: SIEMENS GAMESA RENEWABLE ENERGY A/S
    Inventor: David Stien Pedersen
  • Patent number: 11008459
    Abstract: Glass flakes of the present invention include glass flake substrates and a coating covering at least a portion of the surface of each of the glass flake substrates and composed of a binder. The binder includes a lubricant other than silicone, or a lubricant and an aminosilane. The proportion of the lubricant in the binder is 30 mass % or less.
    Type: Grant
    Filed: February 8, 2017
    Date of Patent: May 18, 2021
    Assignee: NIPPON SHEET GLASS COMPANY, LIMITED
    Inventor: Nobuaki Tai
  • Patent number: 10946554
    Abstract: Disclosed are a prepreg manufacturing device and a prepreg manufacturing method using the same. A prepreg manufacturing device according to an embodiment of the present invention comprises: a first resin inflow part which is formed inside an upper mold, receives a resin supplied from an extruder, and discharges the resin to a reinforced fiber flowing to a lower part in the upper mold; and a second resin inflow part which is formed inside a lower mold, receives the resin supplied from the extruder, and discharges the resin to the reinforced fiber flowing to an upper part of the lower mold.
    Type: Grant
    Filed: December 27, 2016
    Date of Patent: March 16, 2021
    Assignee: LG HAUSYS, LTD.
    Inventors: Kang-Hyun Song, Jong-Sung Park, Hee-June Kim, Hee-Jung Lee, Young-E Moon
  • Patent number: 10816113
    Abstract: A process for producing a thermoplastic composite pipe is provided. The thermoplastic composite pipe thus produced contains a liner, two or more composite layers composed of tape laminas, and a single- or multilayer intermediate lamina arranged between different composite layers. Composite formation between identical polymers in the process achieves improved adhesion. The thermoplastic composite pipe is especially suitable for offshore applications in oil or gas production.
    Type: Grant
    Filed: January 9, 2018
    Date of Patent: October 27, 2020
    Assignee: Evonik Operations GmbH
    Inventors: Jasmin Berger, Hans Ries, Juergen Franosch, Rainer Goering, Horst Beyer
  • Patent number: 10780614
    Abstract: A system for forming stacked material includes a housing defining an interior space. The housing includes a bottom wall and a side wall coupled to the bottom wall. At least one tool is configured to shape the stacked material. The at least one tool is disposed within the interior space. A membrane extends at least partially over the bottom wall and is spaced a distance from the bottom wall. The membrane is configured to move towards the bottom wall. At least one intensifier mechanism is disposed in the interior space and is configured to induce a force against a portion of the stacked material and against the at least one tool as the membrane is moved towards the bottom wall.
    Type: Grant
    Filed: May 24, 2016
    Date of Patent: September 22, 2020
    Assignee: General Electric Company
    Inventors: Sultan Shair, Martin Petersen, Andreas Lutz, Krishnan Balaji Thattai Parthasarathy, Stefaan Guido Van Nieuwenhove, Thomas Kluge, James Duvall Bollacker, Anja Lena Nieratschker
  • Patent number: 10738759
    Abstract: The present disclosure is directed methods for manufacturing spar caps for wind turbine rotor blades. In certain embodiments, the method includes forming an outer frame of the spar cap via at least one of three-dimensional (3D) pultrusion, thermoforming, or 3D printing. As such, the outer frame has a varying cross-section that corresponds to a varying cross-section of the rotor blade along a span thereof. The method also includes arranging a plurality of structural materials (e.g. layers of pultruded plates) within the pultruded outer frame of the spar cap and infusing the structural materials and the outer frame together via a resin material so as to form the spar cap. The resulting spar cap can then be easily incorporated into conventional rotor blade manufacturing processes and/or welded or bonded to an existing rotor blade.
    Type: Grant
    Filed: February 9, 2017
    Date of Patent: August 11, 2020
    Assignee: General Electric Company
    Inventors: Christopher Daniel Caruso, Aaron A. Yarbrough, Daniel Alan Hynum, James Robert Tobin
  • Patent number: 10697112
    Abstract: A flame retardant composition containing a phosphorous containing ammonium salt, a crosslinker, and water is provided, and its application to yarn or fabric to provide a flame retardant yarn or fabric. In a preferred embodiment, the yarn or fabric is made from a polyurethane elastomer, such as a spandex. A method to prepare the flame retardant composition and apply it to the fiber or yarn is also provided.
    Type: Grant
    Filed: September 27, 2016
    Date of Patent: June 30, 2020
    Assignee: SUPREME CORPORATION
    Inventors: James O Threlkeld, Matthew L. Kolmes
  • Patent number: 10576662
    Abstract: A method of forming a fiber-reinforced molding compound. The method includes establishing a melt stream of a source material including a first polymeric material having a first melt temperature in an extruder and dosing a composite material into the melt stream. The composite material includes pre-impregnated reinforcing fibers comprising reinforcing filaments and a second polymeric material having a second melt temperature greater than the first melt temperature. The composite material has at least 30% of the reinforcing filaments protected by the polymeric material such that the polymeric material surrounds each filament completely forming a barrier between it and an adjacent filament in the at least 30% of the filaments. The temperature of the melt stream at dosing is below the second melt temperature. The method includes forming a molding compound from the source and composite materials. The method includes dispensing the molding compound to produce a part.
    Type: Grant
    Filed: April 25, 2019
    Date of Patent: March 3, 2020
    Assignee: AERLYTE, INC.
    Inventor: Christopher Johnston, VII
  • Patent number: 10527023
    Abstract: The present disclosure is directed methods for manufacturing spar caps for wind turbine rotor blades. In certain embodiments, the method includes forming an outer frame or tray of the spar cap via at least one of three-dimensional (3D) pultrusion, thermoforming, or 3D printing. As such, the outer frame has a varying cross-section that corresponds to a varying cross-section of the rotor blade along a span thereof. The method also includes arranging a plurality of structural materials (e.g. layers of pultruded plates) within the pultruded outer frame of the spar cap and infusing the structural materials and the outer frame together via a resin material so as to form the spar cap. The resulting spar cap can then be easily incorporated into conventional rotor blade manufacturing processes and/or welded or bonded to an existing rotor blade.
    Type: Grant
    Filed: February 9, 2017
    Date of Patent: January 7, 2020
    Assignee: General Electric Company
    Inventors: Christopher Daniel Caruso, Aaron A. Yarbrough, Daniel Alan Hynum, James Robert Tobin
  • Patent number: 10327613
    Abstract: A filtration assembly (100) for a vacuum cleaner includes a filtration member (1) for filtering an impurity, in which an outer circumferential wall of the filtration member (1) is provided with a fixing frame (11) adapted to be fixed in the vacuum cleaner; and an ash tapping part (2) which includes a rack (21), a moving member (22), a gear (23) and a tapping member (24). Two ends of the rack (21) are fixed to the fixing frame (11), the moving member (22) is movably disposed to the rack (21), the gear (23) is disposed to the moving member (22) and meshes with the rack (21), the tapping member (24) is disposed to the gear (23) through a connecting shaft (241) so as to be driven to rotate by the gear (23), and the tapping member (24) is configured to tap the filtration member (1) during rotation to vibrate the filtration member (1).
    Type: Grant
    Filed: May 28, 2015
    Date of Patent: June 25, 2019
    Assignee: JIANGSU MEDIA CLEANING APPLIANCES CO., LTD.
    Inventors: Shenghui Liu, Junying Niu, Yan Zhao, Qi Zhang
  • Patent number: 10134505
    Abstract: A cable has at least one elongated electric conductor and a multilayer insulation surrounding the electric conductor. The multilayer insulation has a first semiconducting layer and an electrically insulating layer. The two layers are made from a silicone rubber based composition. A method for making this cable includes co-extruding the first semiconducting layer and the electrically insulating layer.
    Type: Grant
    Filed: May 19, 2016
    Date of Patent: November 20, 2018
    Assignee: NEXANS
    Inventors: Markus Gasser, Franz Haner, Luc Romann
  • Patent number: 10076876
    Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.
    Type: Grant
    Filed: July 11, 2016
    Date of Patent: September 18, 2018
    Assignee: MARKFORGED, INC.
    Inventors: Gregory Thomas Mark, Antoni S. Gozdz
  • Patent number: 10044050
    Abstract: An electrically conductive sheet material having a base body with fibers, at least part of the fibers having carbon fibers, optionally having channels extending through the base body, capable of providing an electrically conductive and flexible sheet material which has a low electrical resistance and which can be produced on a large scale in the most simple, cost-effective and reproducible manner possible.
    Type: Grant
    Filed: July 15, 2013
    Date of Patent: August 7, 2018
    Assignee: Carl Freudenberg KG
    Inventors: Gunter Scharfenberger, Gerhard Schoepping, Birger Lange, Gerald Jarre, Michael Zaminer, Judith Haller
  • Patent number: 10040252
    Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.
    Type: Grant
    Filed: June 20, 2016
    Date of Patent: August 7, 2018
    Assignee: MARKFORGED, INC.
    Inventor: Gregory Thomas Mark
  • Patent number: 10005200
    Abstract: A system or apparatus and associated method is provided to remove pinholes from bio composite materials in order to increase the strength and functionality of the composites. The apparatus and method uses an inert gas, such as nitrogen, that is introduced into the processing chamber where the fiber and the polymer are combined to form the biocomposite material. The inert gas is introduced through an inlet into the chamber and creates a pressure differential between the interior and exterior of the product mixture to force the air and moisture out of the mixture and through an outlet or vent on the chamber, along with the inert gas and any other gases, thereby preventing or at least significantly limiting the formation of pinholes in the biocomposite product.
    Type: Grant
    Filed: March 6, 2015
    Date of Patent: June 26, 2018
    Assignee: CNH Industrial Canada, Ltd.
    Inventors: James Henry, Satyanarayan Panigrahi, Radhey Lal Kushwaha
  • Patent number: 9925432
    Abstract: A golf club head includes a metallic front body coupled with a rear body to define a substantially hollow structure. The metallic front body includes a strike face and a surrounding frame that extends rearward from a perimeter of the strike face. The rear body includes a crown member and a sole member coupled to the crown member. The sole member comprises a structural layer formed from a filled thermoplastic material and a fiber reinforced composite resilient layer bonded to an external surface of the structural layer. The structural layer includes a plurality of apertures extending through a thickness of the structural layer, and the resilient layer extends across each of the plurality of apertures. The structural layer and the resilient layer each include a common thermoplastic resin component, and are directly bonded to each other without an intermediate adhesive.
    Type: Grant
    Filed: May 26, 2017
    Date of Patent: March 27, 2018
    Assignee: Karsten Manufacturing Corporation
    Inventors: Eric J. Morales, Ryan M. Stokke, Martin R. Jertson, Tyler A. Shaw
  • Patent number: 9922757
    Abstract: A process for making a material adapted for the production of composite parts by a process in which a thermoplastic or thermosetting matrix is diffused within said material. The material includes at least one sheet of unidirectional carbon fibers associated on at least one of its faces with at least one conductive component associated or integrated with a permeable layer in a thermoplastic material or in a mixture of thermoplastic or thermosetting materials.
    Type: Grant
    Filed: October 4, 2016
    Date of Patent: March 20, 2018
    Assignee: Hexcel Reinforcements
    Inventors: Jean-Marc Beraud, Andrea Viard
  • Patent number: 9914244
    Abstract: Method and apparatus for use in curing of a composite charge having an internal cavity. Apparatus includes a flexible bladder adapted to be placed in the cavity for applying pressure on the composite charge during curing. An end fitting is operatively coupled to the flexible bladder. The end fitting defining a bolt bore and a horizontal bore. When a vent bolt is operatively coupled to the bolt bore of the end fitting, the vent bolt and the horizontal bore define a pressure passageway that allows an interior of the bladder to become subjected to external pressure.
    Type: Grant
    Filed: August 4, 2014
    Date of Patent: March 13, 2018
    Assignee: The Boeing Company
    Inventors: Kenneth M. Dull, Gordon M. Cox, Darrell D. Jones, Douglas A. McCarville, Michael K. Louie, Robert L. Anderson
  • Patent number: 9908145
    Abstract: A method of manufacturing an object. A thermoplastic matrix material is melted to transform it into liquid matrix material. The liquid matrix material is fed into a chamber via one or more matrix inlets. A fiber is also fed into the chamber via a fiber inlet. The fiber in the chamber is contacted by the liquid matrix material. A coated fiber is extruded from an extrusion outlet of the chamber onto a substrate, the coated fiber comprising the fiber with a coating of the liquid matrix material, the substrate comprising a previously extruded coated fiber. The fiber moves in and out of the chamber at the same velocity relative to the chamber. The coating fuses with the previously extruded coated fiber and solidifies after it has fused with the previously extruded coated fiber. Relative movement is generated between the extrusion outlet and the substrate as the coated fiber is extruded from the extrusion outlet.
    Type: Grant
    Filed: March 18, 2014
    Date of Patent: March 6, 2018
    Assignee: AIRBUS GROUP LIMITED
    Inventors: Benjamin Farmer, William Kessler, Jonathan Meyer, Andrew Hawkins
  • Patent number: 9745196
    Abstract: In order to obtain a graphite film having an excellent thermal diffusivity, a high density, and excellent flatness without flaws, recesses and wrinkles on the surface, the process for producing a graphite film according to the present invention comprises the graphitization step for a raw material film made of a polymer film and/or a carbonized polymer film and/or the post-planar pressurization step for the film in this order to prepare a graphite film, wherein the graphitization step is a step of thermally treating two or more stacked raw material films at a highest temperature of 2,000° C. and includes a method of electrically heating the raw material films themselves and/or a method of thermally treating the films while applying pressure to the films planarly, and the post-planar pressurization step includes a method of planarly pressurizing the one raw material film or the multiple stacked raw material films after graphitization by single-plate press or vacuum press.
    Type: Grant
    Filed: November 1, 2016
    Date of Patent: August 29, 2017
    Assignee: KANEKA CORPORATION
    Inventors: Yasushi Nishikawa, Shuhei Wakahara, Mutsuaki Murakami
  • Patent number: 9732026
    Abstract: The presently disclosed and/or claimed inventive concept(s) relates generally to oligomeric reaction products formed by the depolymerization of polyethylene terephthalate polymers and methods thereof. More specifically, the presently disclosed and/or claimed inventive concept(s) relates to oligomeric reaction products formed by the depolymerization of polyethylene terephthalate polymer obtained from, for example but not by way of limitation, waste products, such as beverage containers made from polyethylene terephthalate (PET). The oligomeric reaction products can, in one embodiment, be used as a starting material for polyurethanes. The presently disclosed and/or claimed inventive concept(s) also relates to processes for producing oligomeric reaction products from the depolymerization of polyethylene terephthalate.
    Type: Grant
    Filed: December 17, 2013
    Date of Patent: August 15, 2017
    Assignee: Resinate Technologies, Inc.
    Inventors: Rick Tabor, Daniel James Seyer, Kristopher M Felice, Adam W Emerson, Matthew Thomas Brown, Kyle Harris McGrath, Mickey Kellerman, Kevin Anthony Rogers, Jack Rogers Kovsky, Matthew James Beatty, Eric David Vrabel
  • Patent number: 9522505
    Abstract: A fiber bundle processing device (filament winding device (100)) that processes a fiber bundle (Fb) having a heat-curable resin impregnated therein, characterized by: comprising a curing device (45A) capable of applying heat to the fiber bundle (Fb); and the curing device (45A) curing or semi-curing some of the resin impregnated into the fiber bundle (Fb), when the fiber bundle (Fb) is partway through being guided into the fiber bundle processing device (filament winding device (100)).
    Type: Grant
    Filed: March 8, 2013
    Date of Patent: December 20, 2016
    Assignees: MURATA MACHINERY, LTD., TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Motohiro Tanigawa, Daigoro Nakamura, Tadashi Uozumi, Ken Hatta
  • Patent number: 9508471
    Abstract: The invention relates to a material (I) adapted for the production of composite parts by a process in which a thermoplastic or thermosetting matrix is diffused within said material, comprising at least one sheet (1) of unidirectional carbon fibers (2) associated on at least one of its faces with at least one conductive component (5) associated or integrated with a permeable layer (3a, 3b, 10) in a thermoplastic material or in a mixture of thermoplastic or thermosetting materials, said permeable layer being in the form of a fabric, a powder, a porous film, a knit, or, preferably, a non-woven (3a, 3b, 10), a process for fabricating composite parts using such a material and the composite parts that can be obtained by such a process.
    Type: Grant
    Filed: March 28, 2013
    Date of Patent: November 29, 2016
    Assignee: Hexcel Reinforcements
    Inventors: Jean-Marc Beraud, Andrea Viard
  • Patent number: 9499955
    Abstract: An apparatus and method is provided for lining the wall of a manhole. The apparatus may include a liner assembly, which includes an expansion device, an auxiliary bladder, a primary bladder, and a liner. The auxiliary bladder is first inflated near the top of the manhole. Next the primary bladder may be expanded to press the liner against the wall of the manhole. The liner, being impregnated with a resinous material, is pressed against the wall until the resinous material cures and hardens. The expansion device, auxiliary bladder, and primary bladder are then removed from the manhole. The result is a repaired manhole wall.
    Type: Grant
    Filed: March 20, 2013
    Date of Patent: November 22, 2016
    Assignee: LMK Technologies, LLC
    Inventors: Larry W. Kiest, Jr., Jason M. Mathey
  • Patent number: 9370896
    Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.
    Type: Grant
    Filed: June 5, 2014
    Date of Patent: June 21, 2016
    Assignee: MARKFORGED, INC.
    Inventor: Gregory Thomas Mark
  • Patent number: 9327452
    Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to drag the filament from the conduit nozzle.
    Type: Grant
    Filed: September 8, 2015
    Date of Patent: May 3, 2016
    Assignee: MARKFORGED, INC.
    Inventors: Gregory Thomas Mark, Antoni S. Gozdz
  • Patent number: 9289936
    Abstract: A die and a method for impregnating at least one fiber roving with a polymer resin are disclosed. The die includes an impregnation section comprising an impregnation zone configured to impregnate the roving with the resin. The die further includes a passage at least partially defined in the impregnation section and in fluid communication with the impregnation zone, and a pump in fluid communication with the passage. The method includes coating at least one fiber roving with a polymer resin, traversing the coated roving through an impregnation zone of an impregnation section to impregnate the roving with the resin, and applying an external pressure to the impregnation zone.
    Type: Grant
    Filed: December 7, 2012
    Date of Patent: March 22, 2016
    Assignee: Ticona LLC
    Inventors: David W. Eastep, Aaron H. Johnson, Timothy L. Tibor
  • Patent number: 9051444
    Abstract: A process for the manufacture of a prepreg comprising feeding a layer of unidirectional conductive fibers having a defined width, bringing into contact with a first face of the fibers a first layer of resin comprising thermosetting resin, and compressing the resin and fibers together by passing over one or more impregnation rollers, wherein the pressure exerted onto the conductive fibers and resin does not exceed 40 kg per centimeter of the width of the conductive fibers, and the resin being in sufficient amount for the resin to enter the interstices of the fibers and leave a first outer layer of resin essentially free of unidirectional conductive fibers.
    Type: Grant
    Filed: June 25, 2010
    Date of Patent: June 9, 2015
    Assignees: Hexcel Composites Limited, Hexcel Composites, S.A.S.
    Inventors: John Ellis, Emille Fisset, David Tilbrook, Paul Mackenzie, Isabelle Blanc, Lucien Fiore, Bernadette Tizon
  • Publication number: 20150137410
    Abstract: The process of forming a reinforced rubber article comprising, in order, slit extruding fibers having at least a first layer containing a polymer, orienting the fibers monoaxially forming monoaxially drawn fibers having a plurality of voids in the first layer in an amount of between about 3 and 15 percent by volume of the first layer, forming the monoaxially drawn fibers into a fibrous layer, and embedding the fibrous layer into rubber.
    Type: Application
    Filed: January 21, 2015
    Publication date: May 21, 2015
    Inventors: Sujith Nair, Padmakumar Puthillath, Johann Peschek, Charles W. Prestridge
  • Patent number: 8992813
    Abstract: A component made of at least one thermoformable material, having a first layer made of a first material, a second layer made of a second material, and a third layer made of the first material. The three layers form a sheet, which is formed to various shapes, depending upon the part that is to be created. The sheet may be formed to produce the bumper of an automobile, a door panel for an automobile, a flotation device, such as a pontoon for a pontoon boat, or the like. The first and third layers are SMC, and the second layer, or “core,” is disposed between the first and third layers, allowing the strength of the first and third layers to be used more efficiently, compared to a sheet having only the first and third layers, and no core.
    Type: Grant
    Filed: December 20, 2010
    Date of Patent: March 31, 2015
    Assignee: Magna International Inc.
    Inventors: Jeffrey R. Robbins, Jeremy Alan Panasiewicz, Louis Dodyk
  • Patent number: 8920693
    Abstract: A method for the production of a fiber-reinforced, thermoplastic polymer, wherein at least one fiber strand is fed into an extrusion die, wherein the fiber strand is fanned out in the extrusion die, wherein the impregnation of the fiber strand with a polymer melt takes place in the fanned out state, and subsequently the fiber strand impregnated with a polymer melt is extracted from the extrusion die.
    Type: Grant
    Filed: February 1, 2012
    Date of Patent: December 30, 2014
    Assignee: Universität Kassel
    Inventors: Andrej Bledzki, Maik Feldmann, Adam Jaszkiewicz, Sebastian Ossadnik
  • Patent number: 8916073
    Abstract: Disclosed is a method for making a membrane for use as a vacuum bag, a natural rubber vacuum bag made using such methods, and methods for using such a natural rubber bag to form a composite article. One method can include providing a substantially non-porous working surface having a desired shape for forming a vacuum bag, spraying at least one layer of a natural rubber liquid over at least a portion of working surface, and solidifying the natural rubber liquid to form a membrane having a shape substantially corresponding to that of the working surface. The membrane formed being elastically deformable and substantially impermeable for functioning as a vacuum bag in Vacuum Assisted Resin Transfer Molding, debulking, compaction, or similar processes.
    Type: Grant
    Filed: February 25, 2008
    Date of Patent: December 23, 2014
    Inventors: Richard W. Rydin, Robert J. Scrima, Jr.
  • Publication number: 20140370773
    Abstract: An interior component for a vehicle may include a nonwoven fabric impregnated with a resin. The nonwoven fabric and resin are consolidated into a solid sheet devoid of pockets. The interior component may exclude metal coated filler particles and lubricants. The method of making the interior component includes the steps of: forming a nonwoven fabric of a staple fiber and a resin, consolidating the nonwoven fabric and the resin into a solid sheet, and forming the solid sheet into the vehicle component. The vehicle may be an airplane, train, subway car, light rail car, bus, or automobile. The resin may be a polymer selected from the group consisting of polyphenylene sulfide, polyetherimide, polyaryletherketone, co-polymers thereof, and combinations thereof.
    Type: Application
    Filed: June 12, 2013
    Publication date: December 18, 2014
    Inventors: Robin Butler, Joseph C. Moon, Steven F. Nielsen, David Bryan Starrett, Barry Strauss, Bryan P. Thomas
  • Patent number: 8911828
    Abstract: The present invention provides a method of producing a molded article, which can be perform the continuous processes and effectively impregnate a modifying material such as metal complexes in the thermoplastic resin for short period of time. The above object is achieved by providing the method of producing the thermoplastic resin molded article which includes impregnating the pressurized fluid having a modifying material dissolved therein, in thermoplastic resin; discharging the pressurized fluid from the thermoplastic resin in which the modifying material has been impregnated; and continuously molding the thermoplastic resin, in which the modifying material has been impregnated and from which the pressurized fluid has been discharged, into the form of a film.
    Type: Grant
    Filed: June 9, 2010
    Date of Patent: December 16, 2014
    Assignee: Hitachi Maxell, Ltd.
    Inventors: Atsushi Yusa, Yoshiyuki Nomura, Harumi Hieida
  • Publication number: 20140364025
    Abstract: Methods of making prepregs are described. The methods include the steps of forming a fiber-containing substrate, and contacting the fiber-containing substrate with a resin mixture. The resin mixture may include polymer particles mixed in a liquid medium, and the polymer particles may be coated on the fiber-containing substrate to form a coated substrate. The liquid medium may be removed from the coated substrate to form the prepreg. The prepregs may be used to make fiber-reinforced articles.
    Type: Application
    Filed: June 11, 2013
    Publication date: December 11, 2014
    Inventors: Mingfu Zhang, Jawed Asrar, Klaus Friedrich Gleich, Asheber Yohannes
  • Publication number: 20140342119
    Abstract: The invention pertains to a molded part (10) with a visible surface and a rear surface (S1, S2), wherein the molded part (10) features: a substrate (20) of hot-pressed fibrous molding material (21); a coating (30) of at least one polymer material (34, 35); wherein the surface (33) of the coating (30) has at least sectionally a center line average height Ra in the range of 10 to 80 ?m, as well as to a method for manufacturing the molded part.
    Type: Application
    Filed: July 9, 2012
    Publication date: November 20, 2014
    Applicant: FAURECIA INNENRAUM SYSTEME GMBH
    Inventors: Friedhelm Kastell, Peter Günther, Jochen Reichhold
  • Publication number: 20140332996
    Abstract: A method of manufacturing a structural member includes preheating a plurality of fibers to a first temperature, moving the preheated fibers along an assembly line, applying a binder to at least one of the preheated fibers, providing a die shaped to receive the preheated fibers, wherein the die moves together with the preheated fibers along at least a portion of the assembly line, maintaining a temperature of the plurality of fibers at a temperature substantially similar to the first temperature, and compressing the plurality of fibers within the die while maintaining a temperature.
    Type: Application
    Filed: May 7, 2014
    Publication date: November 13, 2014
    Applicant: Neuvokas Corporation
    Inventors: Erik John Kiilunen, Kenneth Brian Keranen, Matthew Paul Kero
  • Publication number: 20140315458
    Abstract: A method of treating silicon carbide fibers comprises phosphating heat treatment in a reactive gas so as to form a coating around each fiber for protection against oxidation. The coating comprises a surface layer of silicon pyrophosphate crystals and at least one underlying bilayer system comprising a layer of a phosphosilicate glass and a layer of microporous carbon.
    Type: Application
    Filed: November 27, 2012
    Publication date: October 23, 2014
    Inventors: Stephane Mazerat, Rene Pailler, Sylvie Loison, Eric Philippe
  • Patent number: 8852475
    Abstract: A system and method are disclosed for producing a continuous filament reinforced thermoplastic profile having consistent cross section. A continuous reinforcing filament is pre-wetted with a first thermoplastic resin and introduced into a die, where it is contacted with a second thermoplastic resin extruded from an extruder at melt state. The temperature of the die is carefully controlled so that the pre-wetted filament and first resin do not cure or solidify until after they have contacted and mixed with the second thermoplastic resin. The mixture temperature is then controlled to make a substantially solidified profile pre-shape. A capping layer comprising a third thermoplastic resin is then co-extruded onto the outer surface of the pre-shape. A multistage die for bringing together the filament and thermoplastic resins and for maintaining appropriate temperatures at each stage of the profile-forming process is also disclosed.
    Type: Grant
    Filed: December 1, 2005
    Date of Patent: October 7, 2014
    Assignee: Saint-Gobain Performance Plastics Corporation
    Inventors: Xixian Zhou, Gregory F. Jacobs, Eric S. Waters
  • Publication number: 20140295723
    Abstract: There are provided curable resin sols comprising an essentially volatile-free, colloidal dispersion of substantially spherical nanosilica particles in a curable bisimide resin, said particles having surface-bonded organic groups which render said particles compatible with said curable bisimide resin. There are also provided compositions comprising such curable resin sol and reinforcing fibers, a process for preparing such compositions, and various articles made using such curable resin sols and compositions.
    Type: Application
    Filed: October 24, 2012
    Publication date: October 2, 2014
    Inventors: James M. Nelson, Wendy L. Thompson, William J. Schultz
  • Patent number: 8840824
    Abstract: Single, continuous PTFE layers having lateral zones of varied characteristics are described. Some of the lateral zone embodiments may include PTFE material having little or no nodal and fibril microstructure. Methods of manufacturing PTFE layers allow for controllable permeability and porosity of the layers, in addition to other characteristics. The characteristics may vary from one lateral zone of a PTFE layer to a second lateral zone of a PTFE layer. In some embodiments, the PTFE layers may act as a barrier layer in an endovascular graft or other medical device.
    Type: Grant
    Filed: October 22, 2010
    Date of Patent: September 23, 2014
    Assignee: Trivascular, Inc.
    Inventors: Joseph W. Humphrey, Jeffry B. Skiba
  • Publication number: 20140272300
    Abstract: This invention relates to an aqueous binder composition containing a) at least one polymer P and b) at least one saccharide compound S, such that an amount of the saccharide compound S is ?10 and ?400 parts by weight per 100 parts by weight of polymer P, wherein an amount of an additional formaldehyde-containing binder is ?50 parts by weight per 100 parts by weight of the summed overall amounts of the polymer P and the saccharide compound S. This invention also relates to a process for producing a shaped articles from granular and/or fibrous substrates where an aqueous binder composition of the present invention is applied to the granular and/or fibrous substrate, the granular and/or fibrous substrate thus treated is optionally shaped and then the granular and/or fibrous substrate thus obtained is thermally treated. This invention also relates to shaped articles obtained by a process of the present invention.
    Type: Application
    Filed: May 29, 2014
    Publication date: September 18, 2014
    Applicant: BASF SE
    Inventors: Christian KRUEGER, Ulrich SCHUETZE, Oliver LABISCH
  • Publication number: 20140175694
    Abstract: Provided is a manufacturing method for a fiber-reinforced resin sheet, the method being able to favorably impregnate a reinforcing-fiber base material with a thermoplastic resin. A fiber-reinforced resin sheet S is manufactured by introducing a reinforcing-fiber base material F in sheet form and a thermoplastic resin P into the gap between a pair of impregnating rolls 10A, 10B and impregnating the reinforcing-fiber base material F with the thermoplastic resin P while rotating the pair of impregnating rolls 10A, 10B. The surface of each of the pair of impregnating rolls 10A, 10B has formed thereon a resin holding layer 12 that elastically deforms along the thickness direction thereof when the impregnating rolls are pressed against each other and holds the molten thermoplastic resin P therein so as to be able to discharge the thermoplastic resin P upon pressing of the impregnating rolls against each other.
    Type: Application
    Filed: September 14, 2011
    Publication date: June 26, 2014
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Kazuhiro Mizuta, Yuji Kageyama
  • Publication number: 20140167333
    Abstract: Methods of forming a curable pre-impregnated composite precursor material with radiation (e.g., actinic or electron-beam) curable resin composition systems are provided, as are the curable pre-impregnated composite precursor materials themselves. The resin systems have reversible temperature-viscosity control, which are advantageously used to form curable pre-impregnated composite precursor materials (pre-preg) that can be cured to form a composite article. The uncured resin composition comprises: (a) an acrylate or a methacrylate monomer; (b) an oligomer species selected from the group consisting of: polyethers, polyesters, epoxies, and combinations thereof; and (c) a photoinitiator. The uncured resin has a first viscosity at 21° C. (70° F.) of ?about 200,000 centipoise (cP) and a second viscosity of ?about 5,000 cP at 65° C. (149° F.) or above.
    Type: Application
    Filed: December 18, 2012
    Publication date: June 19, 2014
    Applicant: Autoliv ASP, Inc.
    Inventors: Michael P. Jordan, Bradley W. Smith, Geoffrey A. Russell
  • Patent number: 8753469
    Abstract: A method of vacuum-assisted RTM includes disposing a resin distribution medium on one surface of a reinforcing-fiber substrate, covering the whole with a bag material, reducing the pressure inside the bag material, and injecting a resin into the resin distribution medium to distribute the resin substantially in in-plane directions and then impregnate the resin into the reinforcing-fiber substrate in the thickness direction.
    Type: Grant
    Filed: March 19, 2008
    Date of Patent: June 17, 2014
    Assignees: Toray Industries, Inc., Mitsubishi Heavy Industries, Ltd.
    Inventors: Shigeru Nishiyama, Fumihito Takeda, Hiroshi Odani, Masumi Mizobata