Abstract: A method and apparatus for treatment of relatively moving substrate materials and the novel products produced thereby created by precise application of high temperature pressurized streams of fluid against the surface of the materials to melt and remove material which imparts a recessed channel to the materials that facilitates separation of the materials. The apparatus includes an elongate manifold for receiving heated pressurized fluid, such as air, disposed across the width of the relatively moving material and having a single slit the full width of the substrate for directing the fluid into the surface of the material. The substrate material is treated with an acrylic resin to eliminate jagged or frayed edges either prior to or after the melting and removal process by means of the high temperature pressurized fluid streams.

Abstract: A method of forming a rigid composite varishaped product by knitting an integral fabric piece in the desired shape and impregnating the knitted piece with a selected settable impregnate which is then set; the products made from the method including the intermediate knitted products and the process for making the intermediate product and the knitting program for directing the needles of the knitting machine on which the intermediate product is made.

Abstract: Process for manufacturing supported, solid, polymeric sheets from: (I) liquids containing components reactable to polymers; and (II) one or more indefinitely long, foraminous substrates. A more or less continuous sandwich is formed of such substrate(s) and, faced on each side of the substrates as a group, film extending beyond the lateral edges of the substrate(s), the plane of the sandwich deviating from vertical by not more than about 45 degrees.

Abstract: A composite beam having a constant stress geometry is provided wherein a varying fiber content in a fiber impregnated resin is employed across the beam's cross section to cause the neutral axis of the beam to shift toward the compressive side. The design provides the maximum deflection in the direction of the load before compressive failure occurs for a given size and shaped beam of equivalent stiffness.

Abstract: A discontinuous carbon fiber reinforced glass matrix composite includes a glass matrix, a plurality of carbon reinforcing fibers dispersed in the matrix, and a plurality of boron nitride reinforcing particles dispersed in the matrix. The composite may be fabricated by mixing glass powder and boron nitride reinforcing particles in a carrier liquid to create a slurry and adding a binder to the slurry. A continuous multifilament carbon fiber yarn is impregnated with the slurry and dried to remove the carrier liquid. The impregnated carbon fiber yarn is cut to a suitable length and is molded in a suitable molding means to form a carbon fiber reinforced glass matrix composite article.

Abstract: This invention relates to composite materials formed by thermoplastic materials reinforced by fibers, and to methods and apparatus for forming such materials, where the thermoplastic and fiber components are such as to impart to the composite materials enhanced strength as compared with materials made previously to this invention. An important distinguishing characteristic of the disclosure is that advancing heated fiber is directed to move in one direction and while a flow of heated thermoplastic material is directed to move in a direction opposite to and in intimate impregnating enclosure of the advancing heated fiber, so that shear forces arising between the advancing heated fiber and the directed flow of thermoplastic material promote wetting and impregnation of the fiber by the thermoplastic material.

Abstract: A mat of reinforcement material, such as glass fiber reinforcement material, is manufactured by forming a layer of continuous strand or chopped fibers on a conveyor belt and conveying the layer along a defined path. At a location downstream of the application of the layer, the layer of fibers is coated with a binder in the range of 2.0-10.0 weight percent, either a microwave-sensitive binder or an ultraviolet-sensitive, binder and the binder-coated layer is fed into a radiation tunnel which includes a compression stage and a curing stage. In this radiation tunnel, the binder-coated layer is compressed to a desired density-thickness ratio and cured, the compression and curing occurring in stages, and the resulting mat is taken from the conveyor belt and wound up for storage.

Abstract: Method of producing a single-phase composite structure of filamentary and non-filamentary semicrystalline morphology made from the same polymer, which is of a type capable of gelling in a suitable solvent and of being deformed into a high-modulus, high-strength product. Layers of the polymer in sheet form are interleaved with at least one layer, also of that polymer, made from filaments thereof. The method of making the product may involve heating a sheet of UHMWPE or other polymer gel (5% UHMWPE in 95% paraffin oil, by weight) to 125.degree. C., applying a knitted UHMWPE high modulus, high-strength structure on one side thereof, extracting the non-volatile paraffin oil therefrom with hexane, and evaporating the hexane.

Abstract: A fibrous preform (10) of the component to be manufactured is conformed in the desired shape with the desired degree of compacting, prior to densification by chemical vapor deposition. The conformation is achieved by linking the preform (10) onto a rigid shaping device (12) by threads (30) that traverse the preform (10) and pass through holes (14) in the shaping device. The linking threads (30) are made of carbon or ceramic. Prior to the linking, a covering layer (16) may be arranged on the face of the preform (10) opposite to the one turned towards the shaping device.

Abstract: The shaping of the fibrous texture is at least partly achieved by applying a deformable layer or strip, such as a cloth, made from a material having a thermal expansion coefficient different from that of the material constituting the fibrous texture. The layer or strip is stretched over the fibrous texture or is held in position against the texture by being wound over in order to obtain the degree of compaction wanted for the fibrous texture. The texture is densified by chemical vapor infiltration of the material constituting the matrix of the composite.

Abstract: In the production of a fastener, reinforcing fibers (20) are wetted out in a bath (22) of thermoset resin, drawn together into a wetted cable (23) which is placed in a `U`-shaped die recess of a first die part (24), having parallel inner side walls (25), a second part (29) of the molding die having side walls (30) and a concave die surface then closes the recess by slidably engaging the parallel inner side walls (25), and pressure is applied to the wetted cable without expulsion of wetted fibers. Both die parts (25, 29) have die surfaces which include contours (31) of fastener surfaces, which may be outstanding threads, or annular buttress type projections radiating from the shank .

Abstract: Process for producing a composite material in which a cellulosic substrate is treated with a solution of a polyfunctional isocyanate in an aprotic swelling solvent and the substrate is then compressed to form the composite material. The substrate may take the form of wood chips, wood particles, wood flakes, wood fibers, wood flour, ground wood, wood veneers and wood laminates, paper, card, straw, refined cellulose such as cotton or viscose and plant fibers such as bamboo or palm fiber.

Abstract: Water-dispersible polyester fiber whose water-dispersibility is improved, and precursor filament tow are prepared by an improved process involving treatment of undrawn polyester filaments with a very small amount of caustic, when freshly-extruded, in a spin-finish.

Abstract: A method for the production of fiber reinforced palstic composites, in which a continuously moving array of fibers is impregnated with resin and fast cured as it passes through a shadow boundary created by a source of radiant energy such as ultraviolet light. The method is useful for the production of axial composites such as tubes, pipes, conduits, ducts and the like, which may be created without mandrels by passing the array of fibers through closed dies. The method is also useful with open or rolling dies to create nonaxial composites such as wall panels, guard rails, vehicle body parts, and the like.

Abstract: A process for making polyimide sheet molding compounds which involves the preparation of a polyimide precursor solution of adjusted viscosity that includes a mixture of high and low boiling alcohols, and which also includes monomeric reactants including a diester of an aromatic dianhydride, an aromatic diamine, a monoester of norbornene dianhydride, the reactants being present in a relative molar ratio selected to yield a polyimide having a desired molecular weight. The solution, which further contains particular amounts of staple reinforcing fibers is deposited as a sheet between two carrier film layers and is partially dried to remove the low boiling alcohols.

Abstract: A method of manufacturing a composite material formed of a fibrous reinforcement and a silica based ceramic or vitro-ceramic matrix. The method includes impregnating the fibrous reinforcement by means of a sol-gel process wherein premature crystallization of the matrix obtained from the sol is hindered by addition to the sol of a crystallization retarding agent, and hot pressing the resulting material. The composite material formed has a residual porosity without the addition of nucleating agents of about less than 10%.

Abstract: A vascular patch for closing an incision in a blood vessel includes a base layer of expanded polytetrafluoroethylene (PTFE) having an outer coating of an elastomeric, biocompatible material such as polyurethane to minimize suture hole bleeding. Suture guidelines are formed upon the ablumenal side of the PTFE base layer prior to application of the elastomeric coating to facilitate proper and consistent placement of sutures. A colorant is added to the elastomeric coating to identify the ablumenal side of the vascular patch. The vascular patch is made by mounting an expanded PTFE tube upon a mandrel and applying a water based PTFE ink as a helical stripe about the outer surface of the PTFE tube to form the suture guidelines. The striped PTFE tube is then dip-coated or spray-coated with the elastomeric coating to which the colorant has been added. The PTFE tube is slit to form a flat sheet from which vascular patches are cut.

Abstract: A spring consisting of a rope having a plurality of strands each containing a plurality of monofilaments, and a cured binder which has saturated the rope under pressure to cause it to be self-sustaining in spring form. A method of fabricating a spring including the steps of providing a conventional rope composed of a plurality of monofilaments, saturating the rope under pressure with a binder to form a combined rope and binder, forming the combined rope and binder into a predetermined spring shape, and curing the binder to cause the spring to be self-sustaining in the formed predetermined spring shape. A self-damping spring formed by the foregoing method wherein the rope is of the twisted type, and the amount of damping being dependent on the angularity of the twisting. A spring consisting of a first portion of a rope impregnated with binder to hold the spring in a self-sustaining shape and an untreated second rope portion formed integrally with the first portion.

Abstract: A process for preparation of a carbon fiber composite reinforced carbonaceous material characterized in that using carbon fibers or the raw material fibers of the carbon fibers as the base material, the surfaces of said base material fibers even to the surface of the single fiber are uniformly and completely coated with dormant mesophase pitch and/or isotropic pitch, and after said base material has been molded, the resulting product is subjected to carbonization treatment or graphitization treatment.

Abstract: A molding apparatus and method are provided for molding hollow articles. Resin impregnated fibers are passed through a mold cavity as defined by a heated die and around a mandrel which extends through the mold cavity. The mandrel is stabilized by a mandrel stabilizer fixedly positioned downstream from the inlet end of the die. The mandrel stabilizer includes a plurality of elongated members spaced around the mandrel, wherein each elongated member has an end in contact with the outer surface of the mandrel.

Abstract: Apparatus for pultruding thermoplastic, resin-impregnated, fibrous substructures heats the substructures to a temperature just below the melting temperature of the resin. The heated substructures are then simultaneously pulled through a passage to conform them to a desired cross section. At least a portion of the perimeter of this passage is formed by a wave guide. The wave guide is vibrated at ultrasonic frequency in a predetermined direction so as to direct the ultrasonic vibration into the substructures within the passage. The application of the ultrasonic vibration stimulates the flow of the resin in the heated substructures. Pressure is applied to the flowing substructures within the passage to consolidate them into an integral structure conforming to the chosen profile. The ultrasonic vibration at low power input does result in some heat transfer to the profile, but the flow rates of the resin exemplify an increase in flow far greater than expected in relation to the temperature increase.

Abstract: In the process for manufacturing thermoplastic polymer articles reinforced with long continuous fibers by pultrusion, including impregnating tufts of fibers with thermoplastic resin, circulating an assemblage of said impregnated tufts in a heat assembly so as to melt the resin, and then hot shaping the article in an appropriate die to give it essentially its final shape before passing it through a second cooling die, the improvement including compressing the assemblage of impregnated tufts in the heated assembly consisting essentially of a flat die having an inlet zone and an exit zone, the inlet being wide enough to allow the initial volume of the impregnated tufts to pass through and a horizontal gap adapted to be varied in thickness, and allowing the emerging assembly of impregnated tufts to be brought to the shape of a sheet of minmimium thickness before shaping, and the flat die and rigid polyvinyl chloride article prepared by the process.

Abstract: Drawn polyester multi-filament yarns, preferably prepared by a coupled process of spin-drawing, and of fabrics and garments thereof, are prepared by an improved process involving treatment of freshly-extruded polyester filaments with caustic in the spin-finish, so as to improve moisture-wicking properties.

Abstract: Solid polyester fiber in spun yarns, and fabrics and garments and precursor staple fiber and filamentary tow, are prepared by an improved process involving treatment of freshly-extruded undrawn polyester filaments with caustic in the spin-finish, so as to improve moisture-wicking properties.

Abstract: Polyester filaments in spin-oriented feed yarns, such as DTFY, and in draw-textured and other drawn yarns therefrom, and in fabrics and garments of such yarns, are prepared by an improved process involving treatment of the freshly-extruded polyester filaments with caustic in the spin-finish, so as to improve moisture-wicking properties.

Abstract: Geogrid net-like structures including compound composite reinforced strands.

Abstract: Ceramic insulation has a mat of intersecting, discrete ceramic fibers bonded with a sol-gel glass binder. A fabric-reinforced glass coating is bonded to at least one surface of the mat. The insulation is prepared by forming a slurry of ceramic fibers, molding the slurry to form a soft felt mat, drying the mat, and incrementally introducing the binder into the mat with a multiple-impregnation technique, which controls shrinkage of the ceramic fiber mat. The fabric-reinforced glass coating is formed by applying a glass fiber cloth to a surface of the ceramic fiber mat and coating the same with a powdered glass. The powdered glass is melted and cooled.The process provides a layering technique that permits formation of a continuous fibrous structure having layers that impart distinct characteristics at desired regions within the structure.

Abstract: Apparatus for producing resin-impregnated fiber tow or strand in the form of prepreg tape. The apparatus includes unique coating wheels for sunface-coating the strand with molten, flowable resin and a kneading section to work the strand and disperse the molten resin uniformly among and between the individual fibers of the strand. The strand, after chilling, has good dimensional stability and is useful as prepreg in forming composite structures.

Abstract: A process for preparing non-planar thermoplastic fiber reinforced composites utilizes drapeable thermoplastic impregnated fiber reinforced prepregs in a pressure thermoforming process employing but one diaphragm. The single diaphragm when initially used is flat, but becomes deformed, following its first use, to the shape of the finished part. The diaphragm thus deformed may be repeatedly used as it will still fit over the prepreg layup.

Abstract: A process relating to the manufacture of a composite component comprising a web and a reinforcement structure. The process includes providing a profiled section constituting a fibrous structure that is rigidified by impregnation with a thermoformable binder. The profiled section provided has a cross-section corresponding to the dimensions of a non-compacted blank of the component to be formed in a single unit with the web and the reinforcement structure. A blank of the component to be produced is machined from a length of the profiled section. The blank is press formed to obtain a preform having a shape and dimensions approximating those of the component to be produced and the preform is densified by chemical vapor infiltration of a material constituting a matrix within the fibrous structure, after elimination of the thermoformable binder.

Abstract: Continuous glass fiber reinforced composites are made by pultruding the fibers with mixtures of certain silanes and thermoplastic resin in which the silanes have adsorbed onto the thermoplastic resin.

Abstract: Composite materials with matrices of tough, thermoplastic aromatic polyimides are obtained by blending semi-crystalline polyimide powders with polyamic acid solutions to form slurries, which are used in turn to prepare prepregs, the consolidation of which into finished composites is characterized by excellent melt flow during processing.

Abstract: Process for the manufacture of continuous moulded bodies from structures of reinforcing fibres impregnated with thermoplastic plastics, wherein a structure of reinforcing fibres is passed through a melt of the thermoplastic at a pressure of 1 to 800 bar for a length of at least 300 mm and a device for carrying out the process.

Abstract: Low density fibrous mats formed from fibres and thermosetting and thermoplastic binders, transformed by moulding at elevated temperatures are used for the production of mouldings. Such fibrous mats are produced in that a mixture of fibres and binders is spread out to form a fleece and the latter is compressed or compacted to a mat at high temperature. For the planned influencing of the characteristics of the moulding, while simultaneously reducing the binder requirement and the density, it is proposed that the fibrous mat or blanks thereof is passed through a pair of rollers with polished surfaces and by means of at least one roller binder is applied from the aqueous phase to the side of the fibrous mat facing the same under pressure action and that the fibrous mat is passed through the roller pair at a speed lower than the circumferential speed thereof and following onto the roller pair is passed through a drying zone.

Abstract: A method for producing a carbon electrode which includes directly depositing a carbon material on an electroconductive electrode substrate by chemical vapor deposition using hydrocarbons and/or their derivatives as a starting material, and subjecting the substrate coated with the carbon material to an electrochemical treatment so that the carbon material is doped with a charge carrier material capable of being reversely intercalated therein and deintercalated therefrom. Thereafter, the electrochemically treated substrate is compressed, and a thin plate-shaped carbon electrode with a high density results.

Abstract: A process for producing improved gypsum models and molds of high duplication accuracy is provided. In the process, bundles of carbon fibers of specified length and amount having a sizing agent deposited thereon are treated to remove the sizing agent from the carbon fibers which are then separated into single fibers in water. A major part of hemihydrate gypsum (CaSO.sub.4.1/2H.sub.2 O) powder is then added to the carbon fibers dispersed in water to obtain a gypsum slurry having the carbon fibers uniformly dispersed therein. The slurry is then cast to obtain the models or molds.

Abstract: An oxidation process for stabilization of pitch-based matrices in the fabrication of carbon-carbon composites. By oxidizing a fiber preform impregnated with petroleum-derived mesophase pitch at temperatures in the range of 190.degree. to 300.degree. C. for periods of the order of ten hours, the matrix is fixed in place within the preform so that softening, bloating, and expulsion of the matrix are avoided when the body is carbonized. The invention can also be practiced to increase the carbon yield upon carbonization. Sufficient access porosity must exist in the matrix to permit oxidation throughout the composite body; this is normally formed in a preform due to the mismatch in thermal expansivities of fiber and matrix. Also, the softening point of the pitch must be above the oxidation temperature; this need can be met for most mesophase pitches.

Abstract: A composite implant prosthesis comprising a core constructed from a plurality of carbon fibers, a first casing formed from a braided sheath of carbon fibers and a second casing enclosing the core and first casing to define an outer surface contour for the composite implant prosthesis. The method for constructing the composite implant prosthesis includes the steps of pultruding the core from a polymer impregnated tow, braiding the first casing to the pultruded core and applying the second casing thereto. The pultruding and braiding steps are performed in a continuous process while the second casing is applied to a discrete element formed from the core.

Abstract: An elastomer coated bias fabric for reinforcing power transmission belts and the like is disclosed wherein one face of the fabric is provided with an uncured, tacky, carboxylated elastomeric composition. In one embodiment, the fabric is prepared by pre-impregnating the fabric with a neoprene latex composition followed by coating the neoprene composition on both faces of the fabric, and after drying the fabric, overcoating one face only of the coated fabric with a tackified, carboxylated neoprene latex composition. A method and apparatus for manufacturing the coated fabric is also disclosed.

Abstract: Composites comprised of reinforcing fibers in a continuous matrix of poly(biphenylene sulfide) resin and methods of producing such composites are provided. The poly(biphenylene sulfide) resin is produced by reacting 4,4'-difluorobiphenyl with an alkali metal sulfide in a polar organic compound whereby the resin has a high melting point and a high melt viscosity, and the composites formed therefrom have excellent mechanical properties and retention of mechanical properties at high temperatures.

Abstract: A process for increasing the damage tolerance in thermoset composites without loss of processibility or mechanical properties of the thermoset, by controlled solubility of a thermoplastic filler in the base thermoset. The process includes mixing spherical particles of a selected thermoplastic, such as polyimide, of particle size ranging from about 10 to 80 microns, with a hot thermoset resin, such as a bismaleimide, to form a uniform dispersion of the resin mixture, employing about 5 to about 40% of the thermoplastic by weight of the mixture of the two resins. The particles of thermoplastic are non-agglomerating and insoluble in the resin mixture. The hot resin dispersion is then applied to fiber reinforcement, such as carbon fiber tapes, to form pre-pregs. Upon curing the thermoset at elevated temperature, the thermoplastic particles dissolve in the thermoset resin, forming a composite with no definable boundary interfaces between the thermoplastic and thermosetting resins.

Abstract: Apparatus and method for the impregnation of a continuous length of multifilament or multifiber yarns with a molten thermoplastic polymeric resin includes a member for spreading the multifilaments or multifibers apart during their immersion in a bath of the molten resin. The shape, configuration and location of the member facilitates the homogeneous impregnation, particularly with highly viscous melts, to produce a uniform and thorough encapsulation of the filaments or fibers.

Abstract: A process is provided for producing thermoplastic resins reinforced with long fibers in which rovings are impregnated with a wetting thermoplastic polymer by means of a die and a baffle zone, then taking up the impregnated rovings in a second die where they are then covered with a thermoplastic polymer.

Abstract: An edge guard and method of manufacture are disclosed wherein plastic is extruded onto wires which may be individual wires taken from reels or a wire mesh screen.

Abstract: A process for providing a design patterns in a material wherein a selected medium is applied to the material, the material being positioned adjacent a surface of a template which surface has selected surface characteristics either topographical or non-topographical in nature. The material is held against the template surface at a selected pressure and for a selected time period, at least a portion of the medium coming into contact with the template surface, the adhesive and conesive forces of the material, the medium, and the template interacting with each other to generate a unique design relief pattern on the surface of the material which pattern differs from the pattern characteristics of the template. The material is then suitably dried. The viscosity and amount of the medium, as well as the pressure used, are selected to lie within specified ranges to produce heavy or light relief patterns on permeable or non-permeable materials.

Abstract: A process for producing high performance, metallic coated staple fibers and nonwoven insulating webs made up of such fibers includes providing a nonwoven substantially two-dimensional web of fibers wherein at least a portion of 50 percent of the fibers are exposed to one or the other side of the web. This web is metallized with a low emissivity metal(s) and/or alloy(s) to produce a coated web wherein at least 50 percent of the surface area of the web fibers are coated with metal and or alloy. The coated web is shredded into individual, staple fibers which are thereafter united to produce a nonwoven, lofty three-dimensional insulating web having a density of between about 0.02 to 2 pounds per cubic foot.

Abstract: A method for the production of a carbon electrode includes directly depositing a carbon material on an electroconductive and flexible electrode substrate by chemical vapor deposition using gaseous hydrocarbons as a starting material, filling the carbon material directly deposited on the electrode substrate with a charge carrier material capable of being reversibly intercalcated therein and deintercalated therefrom, and compressing the electrode substrate filled with the charge carrier material, resulting in a thin plate-shaped carbon electrode.

Abstract: In the process for the manufacture of a polyamide composite material reinforced with long fibers, the improvement comprising impregnating the fibers with a polyamide oligomer or prepolymer, heat-treating the impregnated fiber to increase the length of the polymer chain, and then shaping the impregnated fiber by pultrusion.

Abstract: Poly(arylene sulfide)/long carbon fiber laminates containing small amounts of added crack inhibiting agent such as polyethylene have reduced levels of microcracking. The polyethylene can be introduced as a finely divided powder in a slurry prepreg process or can be compounded with the poly(arylene sulfide) and extruded as a film for stacking with carbon fabric.

Abstract: An aqueous coating composition is provided for thermoplastic films comprising(i) from 1 to 10 weight percent based upon the total weight of the coating composition, of a sulfonated copolyester consisting essentially of the polyester condensation product of the following monomers or their polyester-forming equivalents:(A) about 65 to 95 mole percent of isophthalic acid;(B) about 0 to 30 mole percent of at least one aliphatic dicarboxylic acid of the formula HOOC(CH.sub.2)--.sub.n COOH, wherein n ranges from about 1-11;(C) about 5 to about 15 mole percent of at least one sulfomonomer containing an alkali metal sulfonate group attached to a dicarboxylic aromatic nucleus; and(D) stoichiometric quantities of about 100 mole percent of at least one copolymerizable aliphatic or cycloaliphatic alkylene glycol having about from 2 to 11 carbon atoms,(ii) from 0.