Abstract: A method of fabricating a diffractive optical element includes the steps of: etching a negative of a desired multi-level diffraction pattern onto a molding surface of a quartz master element using photolithography, assembling the master element as a portion of a mold, and injecting a plastic molding composition into the mold and against the molding surface of the master element to injection mold a diffractive optical element, whereby the optical element has the desired diffraction pattern on its surface. The diffraction pattern is preferably formed on the quartz master using VLSI photolithography.

Abstract: To produce fiber-reinforced composites, a continuous fiber strand is pulled through an agitated aqueous thermoplastic powder dispersion via deflectors. Following removal of the water phase the thermoplastic powder is heated and melted onto the fibers. Finally the fiber strand is impregnated with a thermoplastic melt by melt pultrusion.

Abstract: Discrete carbon or other electrically conductive fibers are added to a fluid formulation of settable resin in a bath, and a number of tows of non-conductive fibers, for example glass, are drawn through the bath, entraining and partly aligning the conductive fibers and being wetted by the resin. The tows are then bunched into a bundle, causing most of the conductive fibers and concentration zones to render the moulded product conductive to electrostatic charge.

Abstract: Apparatus and methods are provided for producing a long fiber-reinforced thermoplastic resin compositions by initially loosening a continuous fiber bundle by a fiber loosening device so as to form a moving web-like continuous fiber bundle. At least one side of the moving web-like continuous fiber bundle which passes through the die is coated with a thermoplastic resin melt extruded through a slit disposed in the die by an extruder. The slit has substantially the same width as that of the web-like continuous fiber bundle to provide an even supply of the resin melt in the width direction of the web-like continuous fiber bundle. However, the slit has a spacing which changes at a point in the widthwise direction of the web-like continuous fiber bundle so as to be increased as the point is more remote from a feed port and have a constant spacing in the flowing direction of the thermoplastic resin melt.

Abstract: An endoprosthesis of compact thermoplastics including composite materials is disclosed. The endoprosthesis includes a plurality of prefabricated fibers such as carbon or aramid. Thermoplastics such as polyacrylates, polyaryl ether ketones, polycarbonates, polyether sulphones, polyethylenes or polyproplyenes are used as a binding agent. The prefabricated fibers have an internal core with predominately longitudinally oriented fibers and an enclosing covering with mutually intersecting fibers. The prefabricated fibers are cut to a length which is preferably five times their minimum diameter. The fibers are oriented substantially parallel to the major axis of the endoprosthesis. During molding and even in shallow cross- sections relative to the major axis of the endoprosthesis, each prefabricated fiber is at least partially overlapped by an adjoining prefabricated fiber.

Abstract: Demolding apparatus for reliably and repeatedly mechanically separating contact lens mold assemblies without damaging the contact lens formed therebetween. The mold assembly includes a frontcurve mold having a central mold section with a surrounding flange, and a corresponding backcurve mold also having a central mold section with a surrounding flange, with a contact lens being molded therebetween. A support pallet is provided for supporting the mold assembly. A wedge separating fixture provides at least one separating wedge positioned between the spaced flanges of the mold assembly, and the wedge separating fixture and support pallet are translated relative to each other to progressively separate the frontcurve mold from the backcurve mold.

Abstract: An apparatus for causing the polymerized excess monomer to separate from a molded lens by increasing the surface energy of the flange area of one mold piece, causing the polymerized excess monomer to stick thereto. Specifically when manufactured under inert atmosphere conditions, a particular manifold is needed to supply an oxygen bearing gas, air, to the area to be treated while preventing the oxygen from contaminating the lens manufacturing area of the molds or diluting the nitrogen atmosphere of other lens process areas. It has been found that generation of the ionized oxygen by means of a corona treatment electrode sufficiently increases the adherence of the polymer to the mold piece so treated.

Abstract: Disclosed is an adsorbent fibrous nonwoven structure composed of a matrix of pulp fibers having a first exterior surface and a second exterior surface; and an adsorbent material integrated into the pulp fiber matrix so that the concentration of adsorbent material adjacent the first exterior surface of the nonwoven structure is at least about 60 percent, as determined by optical image analysis, and the concentration of adsorbent material adjacent the second exterior surface is less than about 40 percent, as determined by optical image analysis. This adsorbent nonwoven structure provides useful strength and low-lint characteristics. The fibrous nonwoven structure of the present invention may be laminated together or to surfaces of other materials.

Abstract: A method for providing compact discs with an antipiracy marking and a mold for pressing compact discs for making compact discs carrying an antipiracy marking as well as compact discs comprising an antipiracy marking pattern, the compact disc consisting of a substrate including on one of its sides the information to be read by the compact disc player and on the opposite side an antipiracy marking pattern.

Abstract: A process which includes comminuting a first thermoplastic material, e.g. polypropylene, reinforced with short glass fiber (10-400 .mu.m). 100 parts by weight of the comminuted material are mixed with 11-43 parts by weight of chips of a second thermoplastic material, which is reinforced with long glass fiber (about 10-20 mm). The melts of the two thermoplastic materials should be mutually mixable. The mixture is subjected to thermoplastic forming.

Abstract: A cross-head die for the manufacture of long fiber-reinforced resin structures enhances fiber loosening and resin melt impregnation of fiber bundle near its inlet. A passageway along which the fiber bundle travels is defined between the die inlet and outlet and is in communication with a resin port to allow a resin melt to be introduced thereinto so as to impregnate the traveling fiber bundle. The passageway meanders relative to the common plane so as to establish a plurality of alternating successive peak and valley portions each having a substantially constant pitch dimension as measured at adjacent crossing points of the passageway with the common plane. A first peak or valley portion adjacent to the inlet has a greater height dimension as measured from the common plane as compared to a last peak or valley portion adjacent the outlet.

Abstract: The present invention provides a reinforcing structural rebar. The rebar comprises an inner core formed by pultruding reinforcing fibers through a bath of a first resin material, the inner core typically containing at least about 40 percent by weight reinforcing fibers and an outer cladding of a corrosion resistant and reinforced second resin material.

Abstract: A machine and process for making an ultraviolet cured block for an ophthalmic lens are provided in which a lens is placed at an input port to the machine by an operator. Data related to the lens is fed to or stored in the machine from either a keyboard or a data base. The lens is then collected from the input port for processing and transported, preferably by means of pneumatics, to a block molding point within the confines of the machine. A special adhesive is administered to the surface of a mold unit and the mold unit is then positioned to receive the lens. Pressure is applied to squeeze the lens against the adhesive and the mold. After molding the adhesive onto the lens, the lens and mold are transported via servo slide to a UV station where curing takes place from above the lens. After preliminary curing, the lens and mold unit are taken to a removal station and the lens, together with the adhesive cured to its front surface, is removed from the mold unit, again preferably by means of pneumatics.

Abstract: A method for producing visible marks in molded contact lenses, particularly soft hydrogel contact lenses, by placing a recessed mark configuration in a metal insert. The metal insert is subsequently used to produce injection molding frames, which are then subsequently used in the molding of the final contact lenses. The recessed mark configuration is at least approximately 10 microns deep, has a Volume Index, which is the ratio of the quantity volume below a reference surface minus the volume above the reference surface over the volume below the reference surface, of at least approximately 0.9. The recessed mark configuration also preferably has a ratio of surface roughness (RMS or Ra) to a peak-to-valley (PV) measurement, RMS/PV or of Ra/PV, of greater than approximately 0.15.

Abstract: Apparatus and method for manufacturing a resin structure reinforced with long fibers. A continuous fiber bundle is impregnated with a resin melt while the fiber bundle is being drawn continuously. Thereafter, the continuous resin-impregnated fiber bundle is shaped so as to have a cross-section of the intended final product. The shaped resin-impregnated fiber bundle is then cut at a downstream location. Shaping of the resin-impregnated fiber bundle is accomplished by a plurality of rolls, each having grooves formed on the outer periphery thereof which receive the continuous resin-impregnated fiber bundle. The grooves and the rolls are arranged such that the rolls are placed, in an alternating manner, at upper and lower positions with respect to the fiber bundle which is being drawn and such that the grooves of the rolls on the elevation plane perpendicular to the running direction of the fiber bundle forms a shape of the cross-section of the intended final product.

Abstract: Apparatus and method for manufacturing a resin structure reinforced with long fibers by impregnating a continuous fiber bundle with a molten resin, shaping the resin-impregnated continuous fiber bundle so as to have a cross section of an intended final product; and then taking up the resin-impregnated and shaped continuous fiber bundle shaped with upper and lower endless belts or rolls. A comb-shaped structure is positioned at a location on an upstream side of the endless belts or rolls so as to hold the resin-impregnated continuous fiber bundle between two adjacent teeth thereof. The comb-shaped structure is oscillated in a widthwise direction of the endless belts or rolls with the resin-impregnated continuous fiber bundle held between the two adjacent teeth thereof so as to responsively oscillate the resin-impregnated continuous fiber bundle in the widthwise direction of the endless belts or rolls.

Abstract: A process is disclosed for forming a flexible, electrically conductive fabric by applying to a nonconductive flexible fibrous web substrate an aqueous solution comprising a conductive material and a binder, saturating the web with the aqueous solution, and drying and curing the web. Another process is disclosed for altering the chemical or physical properties of a resin during a production process comprising the steps of treating a fabric with an aqueous solution containing a conductive material, a binder and a resin-affecting compound; applying the treated fabric to a resin and causing the resin-affecting compound to leach from the fabric into the resin; forming an article from the fabric and the resin, and curing the article. A further process is disclosed for treating the fabric by dipping the fabric in an aqueous solution containing a conductive material, a binder, and a resin-affecting compound; nipping the fabric; and drying the fabric.

Abstract: A method for forming a preform mass of thermoplastic material into a lens by compression molding between a pair of molds without the formation of air bubbles or the entrapment of air pockets in the finished lens by preheating the preform mass and molds, and further continuing to apply increased pressure while increasing the temperature or maintaining a predetermined temperature and pressure until the mass has been compressed between the two molds into the shape of a substantially finished lens.

Abstract: A front projection screen for pictorially displaying upon a front face of the screen an image projected onto the front face from a projector comprises a backing member having a front reflective surface and a polarization rotation plate overlaying the reflective surface for rotating the plane of polarization of light reflected from the surface. A sheet of lenticular lenses overlays the polarization rotation plate and a polarizing film overlays the lenticular lens sheet. The polarizing film has non-polarizing segments at a focal point of each of the lenticular lenses so that light from the projector is not attenuated by the film while light from other sources is attenuated.

Abstract: A method of replicating an optically flat surface includes providing a plastic optical element having a machined flat surface. The machined flat surface includes a plurality of ridges thereon. A coating material is applied to an optically perfect flat and the optical element is rolled and positioned on the coating material applied to the optically perfect flat such that grooves between the ridges with the coating material. The coating material sandwiched between the optical element and the optically perfect flat is cured and the optically perfect flat is removed from the cured coating material.

Abstract: A multi-vane structure for incorporation in an aircraft gas turbine engine has vanes of complex geometry made of braided fibers which are continuous about the cavities defined by the vanes. These complex geometry parts are prepared by providing a plurality of removable mandrels, stacking the mandrels along a horizontal axis in a cavity end to cavity end configuration, braiding about the mandrels, cutting the mandrels adjacent the cavity end faces, side stacking the mandrels so the faces are placed in a parallel orientation and molding. Utilizing braided fibers instead of hand lay-up woven fibers eliminates seams and produces cavities having continuous fibers about the periphery thereof which substantially increases the strength and dimensional reproducibly of the part.

Abstract: A method of manufacture is disclosed for a PTCA guiding catheter. The catheter includes a lamination of an inner structural polymer tube, a lubricating means disposed on the inside of the inner structural polymer tube, a reinforcement means embedded at least partially within the inner structural polymer tube, and an outer structural polymer tube embedded at least partially within the reinforcement means and fused at least partially to the inner structural polymer tube.

Abstract: A slurry is molded from ceramic fibers and/or microparticles to form a soft felt mat which is impregnated with a sol prior to drying the mat. A catalyst for the sol is caused to diffuse into the mat by exposing the mat to the catalyst and subjecting the mat to a soak time during which the catalyst diffuses into the mat and causes the sol to gel. The sol-gel binder forms bonds so that the mat is dimensionally stabilized. The mat is dried to produce ceramic insulation, ceramic insulation having a consistent microstructure and a fully gelled sol-gel binder through its entire thickness.

Abstract: In a molded surface fastener manufacturing method, molten resin is injected or extruded from an injection die or an extrusion nozzle, and at the same time, a coarse mesh core sheet is introduced between the extruded molten resin and the circumferential surface of a die wheel, which has a multiplicity of hook-element-forming circumferential cavities. The core sheet is forced against the circumferential surface of the die wheel by a pressing force of a press roller or under a molten resin pressure at the time of injection to pass part of the molten resin through pores of the core sheet and to fill in the hook-element-forming cavities. As a result, a multiplicity of hook elements are molded, and at the same time, the core sheet is embedded integrally in a plate-shaped substrate sheet closer to the hook-element-surface side.

Abstract: A smooth contoured structure is formed from a planar surface by etching mesas of equal height into the surface and heat treating the structure to mass transport material above the desired contour to fill in voids below the desired contour. In an alternate embodiment, an optical element is formed using a patterned layer of sacrificial material and thermally treating the sacrificial layer to form a precursor contour line. The line is then transformed onto a substrate and smoothed to form the optical element.

Abstract: A formable prepreg, and a method of making a formable prepreg by a pultrusion process. The method includes (a) impregnating reinforcing fiber with a thermosetting resin matrix, and (b) passing the resin impregnated reinforcing fiber through a die within which the resin impregnated reinforcing fiber is subjected to conditions sufficient to thicken the thermosetting resin matrix, to provide a formable prepreg. The present invention also provides a method of making a molded article using the prepreg of the present invention.

Abstract: A process for producing a composite part comprising:(i) putting short reinforcing fibers into a transfer mold;(ii) impregnation said short reinforcing fibers with a low viscosity resin;(iii) maintaining said short reinforcing fibers impregnated with by said resin in said transfer mold at a first temperature T.sub.1 known as the gelation temperature until a pasty preform is obtained whose viscosity is suitable for compression molding;(iv) removing said pasty preform from the mold;(v) placing said pasty preform in a compression mold brought to a second temperature T.sub.2, known as the compression temperature, wherein T.sub.2 >T.sub.1 ;(vi) compression molding said pasty preform; and(vii) polymerizing said pasty preform at at least a third temperature T.sub.3 wherein T.sub.3 .gtoreq.T.sub.2.

Abstract: The invention relates to strings for stringed musical instruments, fishing equipment, and sports racquets which are exposed to a suitable solvent or suitable elasticizer compatible with the materials contained in the fibers, bonding resins, or coating resins in the strings, such that partial dissolution of the material in the suitable solvent occurs or absorption of the suitable elasticizer occurs so as to increase the elasticity, increase the flexibility, increase the ductility, or increase the resiliency of the strings.

Abstract: The invention relates to a process and apparatus for manufacturing a body to be reinforced with a fiber-composite material, especially bottles or containers or metal or plastic for holding a pressurized gaseous medium, in which a plurality of light, high-strength inorganic or organic, non-conductive or conductive as well as non-metallic yarns are wrapped around the body, whereby individual fiber strands or fibers are unwound and are bundled and, prior to being wound on the body, are impregnated with a plastic material. The wrapping of the yarns is carried out with controllable, pre-tensioned yarns. During wrapping, the individual yarns are again impregnated with a polymer melt of thermoplastic and each individual wrapping layer is smoothed and/or cooled by a temperature-controlled roller.

Abstract: In a fiber composite plastic composed of plastic composition and fibers, the fibers have a pronounced fiber length distribution, in particular more than 50% by weight of the fibers have a length outside the range from 0.8.times.L to 1.2.times.L, where L is the mean (weight average) fiber length, and the mean fiber length is greater than the critical fiber length of the plastic composition/fiber system.

Abstract: An apparatus for forming reinforcing structural rebar comprising a core of a thermosetting resin containing reinforcing material and an outer of sheet molding compound is provided. The apparatus comprises layer reinforcing material supply, a thermosetting resin supply means, a shaping die, means for impregnating the reinforcing material the reinforcing material with resin, means for pulling the reinforcing material through the shaping die to form the core of the thermosetting resin containing reinforcing material, sheet molding compound supply, guide means for guiding the sheet molding compound onto the core, and mold means for molding the outer layer of sheet molding compound onto the core.

Abstract: An apparatus and method for causing the polymerized excess monomer to separate from a molded lens by increasing the surface energy of the flange area of one mold piece, causing the polymerized excess monomer to stick thereto. Specifically when manufactured under inert atmosphere conditions, a particular manifold is needed to supply an oxygen bearing gas, air, to the area to be treated while preventing the oxygen from contaminating the lens manufacturing area of the molds or diluting the nitrogen atmosphere of other lens process areas. It has been found that generation of the ionized oxygen by means of a corona treatment electrode sufficiently increases the adherence of the polymer to the mold piece so treated.

Abstract: A ceramic composite is provided comprising ceramic fibers, glass microballoons and/or diatoms, bound together with a ceramic reinforcing cloth with a sol-gel ceramic binder. The composite is particularly useful as a high strength, high temperature insulation material.

Abstract: A part is made of a composite material having an alumina matrix by impregnating a fiber texture with a fluid composition containing a liquid precursor of alumina, a thermoplastic resin, and a suspension of alumina powder, and subsequently convening the precursor into alumina. Additional solid fillers may be added to the impregnation composition. The impregnated fiber texture is preferably made by draping and molding plies that are pre-impregnated with said composition.

Abstract: Elongate products are molded in a die from fiber reinforced plastics by drawing a bundle of tows through a bath of resin and between two portions of an open die, which is closed under high pressure, and heated to cure the resin. The die is opened and the product is then partly withdrawn lengthwise, to draw further wetted tows between the die portions, and the die is again closed, clamping the tail end of the already cured product which still projects into the die space, or clamping blocks at its downstream end. Cold clamping blocks also clamp the tows at the die upstream end. The products are subsequently severed externally of the die by cutter wheels.

Abstract: A pultrusion apparatus and process for impregnation of multiple fiber tows with a thermoplastic resin wherein an impregnation vessel having an entrance and an exit end is provided with a fiber control insert formed of spaced cylindrical rings suspended therein, with a resin flow control device being suspended horizontally within the rings. A combined resin meter and profile die is attached to the impregnation vessel exit end with a cooling die connected thereto. A pulling mechanism pulls the fiber tows through melted resin contained within the impregnation vessel and into a stepped decreasing diameter passageway in the resin meter and profile die to remove excess resin and shape the impregnated fiber into a useful structure before it is cooled below the melting point of the resin by the cooling die. In one embodiment, a cut-off station is provided adjacent the pulling mechanism to cut the cooled impregnated fiber structure into the desired lengths.

Abstract: Plastic bristles made of a thermoplastic or thermosetting plastic material are proposed, into which reinforcing fibers in the form of at least one endless fiber bundle are embedded to increase the bending strength, abrasion resistance, and breaking strength. The fibers preferably are composed of glass fibers, aramid fibers, carbon fibers, or high-strength polyethylene fibers. The plastic material of the bristles can be extruded together with the reinforcing fibers, but it is also possible to manufacture the plastic bristles in a pultrusion bed.

Abstract: A method of molding a plastic element having a microstructure embedded therein includes the steps of providing a master having a microstructure therein; casting a liquid surface coating over said master; solidifying the liquid surface coating to form a rigid molding tool containing said microstructure; placing the molding tool into a molding machine; introducing a plastic element into the molding machine; transferring the microstructure from the molding tool to the plastic element; and removing the molded plastic element from the molding machine. The molding tool may also be produced by machining directly into a molding base element a predetermined microstructure without machining through a transfer interlayer. An injection-molded binary optical element produced according to the method of the present invention provides an injection molded optical element which diffracts light.

Abstract: A method of forming an optical element on the surface of a substrate by ejecting a curable light guide forming liquid from a nozzle onto the substrate and curing the curable light guide forming liquid. A waveguide may be formed by moving the nozzle in a linear pattern over the surface of the substrate during ejection of the liquid from the nozzle. Curing the liquid may include exposing the liquid to ultraviolet radiation, and the radiation may be applied to only a small portion of the liquid. A multilayered waveguide may be formed by ejecting a further light guide forming liquid onto the first and curing it. A core and cladding may be formed simultaneously by ejecting core forming liquid from an inner tube and cladding forming liquid from an annulus about the inner tube. The waveguide may be formed in a groove, and a splitter may be formed by branching a second waveguide from a first, or by laying out two parallel waveguides and connecting them.

Abstract: A process for making metallized plastic molding pellets comprising: first metallizing a laminated plastic sheet by sandwiching an electrically conductive metal foil in between two plastic films; secondly slicing the metallized laminated plastic sheet into a plurality of metallized plastic strips; thirdly wetting and binding the metallized plastic strips, which are radially arranged, with a thermoplastic resin matrix to form a metallized plastic bar by pultrusion processing; and finally cutting the pultruded metallized bar to obtain homogeneously metallized plastic pellets for making effective EMI shields.

Abstract: A method for treating contact lenses involves irradiation of the contact lens with high energy radiation while immersed in an aqueous medium such as saline solution.

Abstract: A continuous FRTP prepreg manufacturing apparatus comprises an extruder, a crosshead having a main body internally provided with a resin chamber for containing a molten thermoplastic resin extruded therein by the extruder and joined to the discharge end of the extruder, a cooling unit disposed outside and near the exit of the main body of the crosshead, and a winding unit for taking up a prepreg. A fiber bundle inlet unit and a fiber bundle outlet nozzle unit are provided respectively at one end and at the other end of the main body of the crosshead. Guide rollers and impregnating rollers are arranged within the main body of the crosshead so that a tension is applied to the fiber bundle during impregnation or so that the fiber bundle is expanded during impregnation and is condensed after impregnation.

Abstract: The present invention provides a method of fabricating a dispersion-type liquid crystal electro-optical device comprising a pair of substrates disposed opposite to each other with a space therebetween and provided with electrodes respectively on their inner surfaces, and a liquid crystal mixture containing a liquid crystal and a transparent resin and sandwiched between the pair of substrates. The method comprises steps of: filling up the space between the pair of substrates with the fluid liquid crystal mixture, applying a voltage across the electrodes to apply an electric field to the fluid liquid crystal mixture to collect the charge of the fluid liquid crystal mixture in the vicinity of the electrodes; and setting the transparent resin. The dispersion-type liquid crystal electro-optical device has a high voltage retention and a low transmissivity in the scattering state, and is capable of clearly displaying pictures at a high contrast ratio.

Abstract: A process for producing a carbon fiber reinforced carbon composite material, comprising dispersing a short fibrous bundle of carbon fibers which comprises a plurality of single fibers, preparing a sheet in which fibers are in the two-dimensional random orientation, impregnating with a resin or pitch, laminating and molding, and then applying a baking and densifying treatment, a dispersion degree of the bundle of carbon fibers being controlled based on the formula (1) expressing correlation between the dispersion degree of the bundle of carbon fibers and the mechanical strength of the carbon fiber reinforced composite material:Dispersion degree=A-B.times.coefficient of friction (1)wherein A and B are constants determined experimentally, to produce a carbon fiber reinforced carbon composite material having desired mechanical characteristic.

Abstract: In the manufacture of hats, the shellac stiffening agent typically used for imparting extra stiffness to the final hat product is replaced with an aqueous acrylic or acrylic/styrene emulsion or dispersion having a pH of 4 to 7, the acrylic or methacrylic polymer or copolymer in the emulsion having an acid value of 80 to 120 mg KOH/gm and a glass transition temperature of 17.degree. to 35.degree. C.

Abstract: A biopolymer film and other materials that exhibit nonlinear optical (NLO) properties and a method for making this film. Alignment of biopolymer molecules, which is required for NLO phenomena, is achieved by application of an electric field parallel to the surface of a biopolymer solution as the film is formed. In one embodiment, a solution of poly(.gamma.-benzyl-L-glutamate), PBLG, in methylene chloride is employed. Upon application of an electric field, laminar structures perpendicular to both the field direction and to the film surface are formed. These ordered structures are captured in the film upon evaporation of the biopolymer solvent.

Abstract: This invention relates in general to a method for the formation of films having a controlled molecular orientation prepared from rod-like extended chain aromatic-heterocyclic ordered polymers, and containing a binder in the micro-infrastructure. Such films have high tensile strength, modulus, and environmental resistance characteristics.

Abstract: Disclosed herein are pultruded articles prepared from a reinforcing material and a polyamide matrix made by the process of impregnating a reinforcing material with a polyamide forming reaction mixture and then pultruding the impregnated reinforcing material through a die while polymerizing the polyamide forming reaction mixture to form a polyamide matrix, wherein the temperature of the material being pultruded is at least about at the lower end of the melting range of the polyamide.

Abstract: This invention is directed to a continuous process for producing a molded thermoplastic fiber reinforced article having a high resin concentration in at least one surface thereof. The finished article may be prepared by compression molding and can have a Class A surface. The continuous process includes coating at least one surface of a heated fiber mat core with a melted first thermoplastic resin, passing the fiber mat core into an extrusion zone wherein a melted second thermoplastic resin is extruded onto at least one surface of the fiber mat core and then molding the fiber mat core and thermoplastic resin into a finished article. The continuous process of this invention provides for fast production of molded finished articles such as roof tile, automobile exterior panels, house siding, etc.

Abstract: An apparatus and method for producing an optical recording medium or an optical recording medium substrate sheet forms an photo-curable resin layer on at least one of a substrate sheet and a stamper which undergoes elastic deformation. The stamper bears a pattern corresponding with preformatting information and is brought into close contact with the substrate sheet wherein the photo-curable resin layer is interposed between them and cured.