Abstract: A strong, light-weight flexible bearing, particularly suitable for use in mounting a movable thrust nozzle to a rocket case, is made by stacking reinforced plastic shims, having the forms of concentric, spherical zones, alternately with layers of elastomer and bonding them together. A protective heat and flame barrier is formed by providing an especially refractory outer edge on each shim, which extends beyond the layers of elastomer. Each shim is made by:preparing a mold surface that forms a spherical zone of unique radius; filling a refractory cloth with a curable, liquid resin; placing segments of the cloth on the mold surface in an overlapping arrangement until the desired shim thickness is attained; preparing a second mold surface substantially parallel to the first: clamping this over the cloth segments on the first mold surface; and applying heat and pressure to the cloth segments until the resins are cured.

Abstract: There are disclosed graft polyesters useful as adhesives and coatings and especially useful in processes for sizing spun and continuous filament synthetic organic and inorganic fibrous yarn. One embodiment of the invention is a textile size composition having free carboxyl groups which is prepared in situ on a textile yarn by the application of heat or radiation to a mixture of an unsaturated polyester reactant and a monovinyl monomer reactant comprising an acidic monovinyl monomer having at least one carboxyl group or mixtures thereof with any monovinyl monomer. Desizing can be accomplished by partial neutralization of the size to a pH of at least 6 by reacting the size with a base to render the graft polyester water-dispersible or water-soluble.

Abstract: The speed of pultrusion can be increased and the quantity of pultruded products can be improved by using a polyester resin composition containing 4-10 parts of certain cellulose acetate butyrate resins per 100 parts of polyester resin.

Abstract: A structured, permanently moldable textile sheet is impregnated on the backside only with an aqueous synthetic resin dispersion, comprising a synthetic resin which comprises 75-95% by weight of a thermoplastic component and 5-25% by weight of a plasticizing component. The resultant impregnated sheet is thereby reinforced and can be permanently molded and glued to an underlying surface without additional preprocessing.

Abstract: A method and apparatus for manufacturing lined latex girdles in which one end of a fabric sheath which will form the liner of a latex girdle is sewn or otherwise held closed together and slipped over an annular rectangular frame, with the closed end of the bag disposed in the middle of the annular rectangular frame. A flat form, with curved sides, is first covered with a latex film, and while tacky, is pushed through the frame, engaging the fabric liner. As the form is pushed through the frame, the liner slides over the frame, and contacts the sides of the form. When the form has been pushed completely through the frame, the liner will be supported on the form, which may then be easily withdrawn for final processing. Close tolerances between the dimensions of the form and the frame assist in providing quality control with respect to the interpenetration of the fabric liner and the latex film.

Abstract: A method for manufacturing a resin-reinforced carbon fiber bar product in which thermal setting resin-impregnated carbon fibers are heated to a temperature sufficient to set the resin to semi-solid state, the heated carbon fibers are passed through resilient constriction means to form a bar-like intermediate product, the bar-like intermediate product is cooled, a tape of water-containing cellophane is wound about the intermediate bar-like product in a spiral manner to compress the carbon fibers together, the intermediate bar-like product is pulled in the longitudinal direction while being heated, the thus treated intermediate bar-like product is cooled and the cellophane tape is removed from the intermediate bar-like product to thereby form a complete resin-reinforced bar product.

Abstract: A method for continuous production of corrugated sheets of fiber-reinforced thermosetting resins, wherein a web of pre-impregnated material is corrugated by moving the web on elongated carrier elements arranged at intervals side by side. These elements are advanced along an essentially horizontal path in the corrugating zone and a subsequent heating and curing zone, and by causing the web to hang down to a desired extent between adjacent carrier elements. The carrier elements may be arranged transversely or longitudinally to the advancing direction of the web in order to obtain transverse or longitudinal corrugations. The upper surface of the web may be provided with a layer of surface protecting and decorating, crushed stone material before or after the corrugation operation.

Abstract: A novel addition polyimide based on the use of liquid monomers wherein the essentially solventless prepreg produced therefrom retains good drape, tack and other mechanical properties.

Abstract: Three-dimensional structures providing a plurality of separate interpenetrating, three-dimensional domains or channels or flowpaths, each of said domains or channels or flowpaths being a closed system of connected porosity or permeability and each of said domains or channels or flowpaths being interpenetrating within said structure, have been prepared. These structures are prepared from porous permeable precursor materials having a single three-dimensional domain or channel or flowpath as described above. Suitable precursor materials are provided by the abundant porous carbonate skeletal material of marine life, e.g. the coral Porites skeletal aragonite. For example, by coating the surfaces of such materials with a liquid material capable of being cured or set to a solid, followed by curing or setting and dissolution, e.g.

Abstract: The wrapped insulation of coils of large electric machines--motors or generators--is set by heat and pressure in a press that extends the length of both wrapped legs of the coil and supports the coil so that it is substantially free from stress. The coil may be supported with its wrapped legs level and horizontal, and the press can be adjustable for different coil sizes and configurations. The heat and pressure cycle is operable automatically to suit the requirements of the insulating material.

Abstract: A flexible, e.g. polyurethane, open cell foam sheet is impregnated with a controlled amount of a liquid polymerizable resin system which cures at ambient temperature, and the resin impregnated sheet is immediately chilled at a suitably reduced temperature, e.g. 40.degree. F. or below, to arrest polymerization or hardening. The resulting resin impregnated sheet is stored at such reduced temperature. When needed for adhesive bonding the chilled resin impregnated sheet, cut to the desired pattern or size, is applied between the surfaces of objects to be bonded, e.g. fiber reinforced polyurethane insulation blocks and plywood strips, or such insulation blocks and the steel hull of a liquid natural gas (LNG) container or marine tanker.

Abstract: In the manufacture of products made of starch filled plastics the polymer and starch granules are mixed with a lubricant immediately prior to forming. A feedstock material in accordance with the invention comprises particles of starch granules in admixture with a lubricant such as an oil or wax.

Abstract: A leather-like sheet material bearing a remarkable resemblance to high-quality leathers of natural origin, especially in respect of flatness, bending crimp, grain and feeling, is produced by providing a substrate consisting of a fibrous base material and a porous coating layer with a thin layer of a polymer, subjecting the surface to a specific heat treatment, providing the resulting material with another thin layer of a polymer, and, if desired, embossing the material.

Abstract: A method for supplying a prepreg having substantially no excess resin while at the same time having an aggressive tack. Small discrete amounts of additional resin are selectively applied to a surface of the prepreg sheets in a regular array. The resin is applied at a sufficient viscosity that it does not sink into the prepreg fabric. The additional resin typically covers less than 25% of the surface and constitutes between 0.1% and 3% of the prepreg weight. The additional resin may be applied by a gravure roller having a surface etched with an appropriate array of indentations. A doctor blade partially defines a reservoir of resin in contact with a portion of the gravure roller and wipes the surface, thereby leaving resin only in the indentations. The doctor blade may be oscillated parallel to the roller axis to prevent accumulations of short fibers from impairing the wiping action.

Abstract: Synthetic resin bodies reinforced with fiber, roving or the like can be made, in accordance with the invention, by impregnating the reinforcing material with synthetic resin and then casting a hardenable liquid around the resulting body to form a mold in situ therefor. The synthetic resin material is thus permitted to harden in the solidified mold material whereupon the mold material is removed.

Abstract: A process of inlaying a design in molded simulated marble or the like comprising the steps of applying a release coating to the inner bottom surface of a mold, applying a transparent gel coat on said release coating, smoothing a piece of porous flexible sheet material bearing the design on one face thereof on the gel coat in the mold to conform to the surface of the gel coat with the one face of the piece of cloth bearing the design toward the gel coat, and casting a hardenable marble mix in the mold over the piece of cloth. The marble mix is then allowed to harden for removal of the resultant simulated marble slab from the mold, the piece of sheet material being embedded in the slab with the design viewable through the transparent gel coat.

Abstract: A building element useful in constructing plastic boat hulls and methods of making the element. The building element includes a plurality of glass fibers in the form of roving which are substantially parallel to each other, a resin binding the glass fibers together, and a plastic sheet covering one or both sides.The building element may be continuously made by passing a plurality of strands of glass fiber roving through a perforated guide plate into a trough of resin formed by the bight of a pair of rollers, feeding a plastic sheet over each roller into said bight to protect the rollers from the resin and to form a sandwich structure with the resin impregnated strands of roving being enclosed within the plastic sheets, and cutting across the plastic sheets and resin impregnated glass strands at a desired angle to form a stamp element.The building element may also be made by passing glass fiber roving through a resin pot and winding the roving around a drum which is covered by a polyethylene sheet.

Abstract: This invention is directed to an improved process for making fiber reinforced articles comprising the steps of (a) applying a preformed plastic shell having the configuration of the desired article to a holding fixture therefore having sealing means at the peripheral edges thereof; (b) applying to the surface of the shell fibrous reinforcement material; (c) introducing to the reinforcement material a liquid plastic resin mixture; (d) applying to the surface of the resin mixture-containing reinforcement material a preformed plastic membrane having the configuration of the desired article; (e) sealing the peripheral edges of the membrane to the peripheral edges of the holding fixture to provide a molding system; (f) applying a vacuum to the molding system to compact the molding system and to draw said resin mixture throughout the reinforcement material; (g) hardening the resin mixture; and (h) separating the resulting article from said plastic membrane and said holding fixture.

Abstract: Method for making a laminated ballistic helmet from plural, continuous filament resin-coated layers. A continuous filament bundle, yarn or end is deposited on a plurality of different sized helmet-shaped preforms. A resin is coated upon or impregnated into the continuous filament bundle, yarn or end, either before or after deposition. The resulting resin containing preforms are stacked in nested relation and then molded to produce a bonded, laminated ballistic helmet.

Abstract: Method for making a filter which comprises a plurality of closely juxtaposed tubes made of a filter material and packed tightly in a tubular envelope. Both ends of the tubes are initially closed. The envelope with the tubes is then dipped to a small depth into a hardenable substance, e.g. latex, which fills the gaps between the tubes and on hardening forms a solid bottom on the envelope. A small length of the envelope and tubes is then severed to open one end of the tubes.

Abstract: Method of making a casing reinforced by a stretchable glass fiber preform is disclosed. The casing may be reinforced by metal or a glass fiber mat which is shaped to provide positive engagement with the stretchable fiber preform before its impregnation by a matrix-forming resin.

Abstract: A tennis racket frame is constructed primarily of an elongated hollow tube member having a wall thereof consisting essentially of a plurality of concentric layers of high tensile strength fibers impregnated and bonded together by binder resin, at least two of the layers being helical windings of opposite unidirectional hands, and the head portion of a racket frame having a groove molded therein to receive the loop portions of the strings in recessed relation to the surrounding surface areas of the frame. The frames are made by a method including the use of a special mandrel on which the layers of fiber are wound under controlled conditions providing extra material in the head portion which is formed into the wall of the grooved portion of the head without affecting the overall sectional dimensions of the frame.

Abstract: A method is disclosed for lubricating surfaces which are in temporary frictional contact which comprises introducing between said surfaces a lubricating liquid which can be solidified by heat or radiation and, after said temporary contact is broken, then solidifying said liquid by heating said surfaces or exposing said surfaces to radiation.

Abstract: Self-extinguishing laminates are made by an improved process, wherein individual layers of a carrier material are impregnated with a thermosetting phenolic resin containing a flame-retardant agent and the impregnated layers are placed one above another and bonded together by compressing them at elevated temperature and under elevated pressure to give a hardened laminate. More specifically, finely pulverulent phosphorus pentanitride as a flame-retarding agent is dispersed in the plasticized or non-plasticized thermosetting phenolic resin, with or without a diluent; the phenolic resin, based on its solid matter content, and the phosphorus pentanitride being used in an approximate ratio by weight of 100:4 to 100:15; and the phenolic resin, based on its solid matter content, and the carrier being used in an approximate ratio by weight of 100:80 to 100:150.

Abstract: A resin reinforced fiber structure is formed by drawing fibers under tension, in spaced relation to each other through a bath containing a molten heat curable resin, combining the fibers in mutual contact for removal of excess resin, spreading the fibers for passage through a preheating zone and then in a recombined state through a plurality of radiant heating zones and relatively narrow cold shaping dies in series. The preheating and heating zones provide heated surfaces in spaced relation to the resin coated fibers, effect a viscosity break to enable the resin to more completely wet the fibers and advance polymerization towards a gel point. The narrow cold shaping dies provide the desired shape to the final article and remove excess resin as cure is advanced. The fiber reinforced resin structure at about the resin gel point is passed through a final cold shaping die, and then to a final curing zone.

Abstract: A novel addition polyimide based on the use of liquid monomers wherein the essentially solventless prepreg produced therefrom retains good drape, tack and other mechanical properties.

Abstract: A process and apparatus for the continuous production of fiber reinforced plastic grating articles is provided wherein continuous strands of fibers are coated with a thermosetting plastic resin material and woven into a grate pattern defined by upper and lower molding teeth arranged on continuous upper and lower molding tracks. The molding tracks rotate and cause the molding teeth to mesh, forming a molding cavity, wherein heat is applied to set the plastic resin. The fiber reinforced plastic grating articles formed by this process and apparatus have a unique cross-sectional configuration and arrangement of fibers providing for increased strength and reduced resin usage.

Abstract: An anti-slip tray and the method of manufacturing it. Sheets of paper impregnated with melamine resin and paper sheets impregnated with phenolic resin are stacked in a pile. A loosely woven cloth covers the pile. Its upper face or major surface is covered with a layer of porous PVC which can be decorative. The cloth has a plurality of perforations. The cloth and pile are molded under heat and pressure.

Abstract: A method of making a multitubular sheath comprising providing a porous multitubular fabric impregnated with thermoplastic or deformable polymer, continuously feeding the fabric onto an array of parallel metal rods, one tube to each rod, the rods having straight sizing portions, while holding the rods in a fixed position, the rods having substantially the same cross sectional area over the whole of their length, the fabric at least immediately prior to the sizing portions being substantially at ambient temperature, heating the fabric on the sizing portions so as to permit the fabric to conform to the rod, thereafter cooling the fabric on the rods to solidify or the deformable composite material to set to shape and the tubes to become self supporting, feeding the fabric off the ends of the rods and cutting it to the required length.

Abstract: A fiber reinforced plastic part is fabricated by laying-up upon a properly shaped mold layers of uncured fiber reinforced plastic. The layers are cut through around the outer periphery of the part and its apertures and the waste material left in place during the curing process. The waste material so cut is thereafter pressed away from the finished part material to form a smooth finished part outer periphery and smooth aperture peripheries along the smooth lines established by the cutting process.

Abstract: The creation of controlled hole sizes and locations in uncured reinforced thermo setting plastic material by mechanically perforating the uncured material and "B" staging the material surrounding the perforation by sonic vibration of the mechanical perforating device.

Abstract: A bent pipe of reinforced synthetic resin is produced by supporting a flexible and elastic tubular mandrel in a stiff and straight position, forming layers of fiber impregnated with thermo-hardening synthetic resin about the mandrel, releasing the mandrel from the straightly stiffened position, bending the mandrel in the desired curvature, heat hardening the synthetic resin, and then extracting the mandrel from the bent pipe thus formed and hardened.

Abstract: The disclosure is of impression surface conveyor belting and a method for its manufacture. The belting comprises a plurality of substantially parallel textile yarns of a specific character, integrated (in a unitary structure) with a layer of consolidated staple fibers and encapsulated in a matrix of flexible elastomer or resin. Included in the integral structure is an impression wear surface of partially isolated matrix material containing a portion of the consolidated staple fibers (a fiber bundle) which are continuously anchored in a portion of the non-isolated belting matrix. The belting of the invention is useful to manufacture non-laminated, impression surface, conveyor belts which exhibit advantageous properties of wear resistance, stability in running and structural integrity.

Abstract: A method of making a high temperature fluted core composite radome structure.

Abstract: A decorative high pressure laminate having registered color and embossing is produced by effecting simultaneous embossing and laminating using a three dimensional press plate acting against an overlay sheet containing high flow melamine resin and pigment, so that during the pressing operation the resin and pigment flows laterally from the high pressure areas to the low pressure areas with the result that the underlying print sheet is visible through the overlay sheet in the high pressure areas while the pigment in the overlay sheet in the low pressure areas mask the print sheet.

Abstract: This invention relates to a method and apparatus for fabricating continuously a solidified elongated rod or hollow shapes of various geometric cross sections of fiber reinforced plastic having a smooth surface. A plurality of strand-like fibers are wetted with a liquid, heat-hardenable plastic, the fibers are collected together into a plastic-wetted bundle, the bundle is continuously, in intermittent steps, passed through an elongated die, the die being heated in sequential zones of progressively increasing temperature so as to harden the plastic by the time the bundle emerges in rod form from the die. The bundle is moved through the die intermittently, dwelling for a predetermined time at rest, then moved an incremental distance, permitted to dwell again, until the hardened bundle eventually emerges from the die. The various heated zones of the die serve to initiate and carry the hardening of the plastic to a predetermined point at which the bundle is moved and the cycle is repeated.

Abstract: Apparatus and method for the continuous manufacture of structural shapes are disclosed. Mineral fiber material in the form of continuous strands, webs, or mats, impregnated with a heat-hardenable resin, is passed through a dielectric heater. The material is shaped as it passes through metallic dies that are disposed within the dielectric heater. The electric field between the electrodes of the heater is reduced or shunted at the location of the dies. The heater is arranged so that the maximum electrical field occurs adjacent the entrance to the heater.

Abstract: A process for producing a heat-resistant object comprises drying fibrils of a ligneous material previously immersed in a boiling aqueous salt solution, said drying being continued until the moisture content thereof is about 10 percent, impregnating said dried fibrils with a solution of a polymerizable resin and pressure molding the resulting impregnated fibrils so as to polymerize said resin thereby producing said heat-resistant object.

Abstract: Spherical friction or sliding bearings are produced by first making a laminate from a layer of a thermosetting resin and a layer of material having a low friction coefficient. The thermosetting resin is used to impregnate a first web or fabric. The low friction coefficient material may be provided in the form of a further webbing or fabric, for instance, made of polytetrafluoroethylene. The thermosetting material may, for example, be a phenolic resin which is at this point of manufacture in its A-state and hence tacky. In order to permit the immediate further processing of the laminate with the thermosetting resin still in its tacky A-state, a dry adhesive film which neutralizes the tackiness, is applied to the laminate in sandwich formation which is then cut into pieces or strips of suitable size. The sandwich strips are then placed into a mold and pre-shaped and precision cut at room temperatures while the resin is still in its A-state.

Abstract: An arcuate card-clothed element is manufactured by combining a deformable sustaining element which may for example be a slotted stiffener or a layer of fibre glass with a flexible toothed foundation while the sustaining element is in a deformable condition and shaped to the desired arcuate contour of the card-clothed element, and introducing a hardenable bonding medium such as a resin to hold the foundation in the shape of the sustaining element and convert the sustaining element to a substantially rigid state. The card-clothed element may be made in individual sectors, or may comprise sectors cut from a cylindrical assembly built on a former.

Abstract: The invention relates to a method and apparatus for making hollow, resin-impregnated fibrous fabric articles. Specifically, it relates to a method wherein a reusable mandrel is made sufficiently rigid to receive a lay-up of the article to be manufactured. The rigidized assembly is placed within a female mold, derigidized and expanded to apply pressure from within, thereby forcing the lay-up against the interior of the mold. Heat is applied to cure the resin, producing an article having a very high degree of dimensional accuracy.

Abstract: A composite molded article composed of a backing layer of fiber-reinforced thermosetting resin and an outer layer of a thermoplastic resin which is mechanically interlocked to the backing layer through the fiber reinforcement. In fabrication, a layer of fibrous material impregnated with an uncured thermosetting resin is placed in a mold and a molten thermoplastic resin is injected into the mold. The heat of the thermoplastic resin serves to cure the thermosetting resin and the resulting composite article has a rigid, high strength backing formed of the reinforced thermosetting resin and has a smooth thermoplastic outer surface which is receptive to surface finishes.

Abstract: Porous, fibrous materials such as non-woven polyester or polypropylene web materials, cotton web, paper and other materials are saturated with a storage stable one-package latex composition. The latex composition is modified with a temperature sensitive cross-linking agent and neutralizing agents. The latex composition is tailored such that a fibrous material may be impregnated and dried at controlled temperature whereby a thermoplastic resin saturant web intermediate stock material having thermoset properties is produced. The cross-linking system in the latex composition is later activated in a specific manufacturing process at heat forming and molding temperatures to obtain a specifically shaped manufacture of desired rigidity and flexibility.

Abstract: A boat hull is made by winding a layer of glass-fibre around a male mould, winding a layer of foam sandwich material on top of the glassfibre, and then winding a second layer of glassfibre on top of the foam.

Abstract: Method of continuously molding articles from a fibrous material containing a hardenable bonding material wherein a quantity of fibrous material is supplied to a forming member that engages the surface of the fibrous material and shapes the material into the desired cross-sectional shape. The exterior surface of the shaped fibrous material is then heated so that the bonding material on the exterior surface of the fibrous material cures to form a hard, tough skin on the exterior surface of the fibrous material. Then, additional heat is supplied to the fibrous material to cure the remaining uncured bonding material on the fibrous material so the fibrous material will be held in the desired shape by the cured bonding material.

Abstract: The method of the present disclosure includes preparing a coil which is impregnated with resin to form a resin packed coil, in which the resin is still in a liquid phase, immersing the resin packed coil into a wax in the liquid state, hardening the wax adhering around the resin packed coil, hardening the resin which is impregnated in the coil, and removing the wax, thus obtaining a resin packed coil assembly where the resin is hardened and surrounds the coil.

Abstract: Silicon carbide sintered moldings having a high flexural strength and various excellent properties are produced by mixing SiC powders with a binder of organosilicon low molecular weight compounds or organosilicon high molecular weight compounds, molding the mixture into a desired shape, heating the molding at a high temperature to form SiC sintered molding, impregnating the SiC sintered molding with the above described organosilicon compound and heating the impregnated SiC sintered molding, if necessary, said impregnation and heat treatment being repeated two or more times.

Abstract: A fibre bundle is first formed from loosely entangled fibres. A sheath is formed over the fibre bundle and one end is dipped into an urethane prepolymer to fill the spaces among fibres with the urethane prepolymer. After removal from the prepolymer it is left to stand for a period of time during which the constituents in the urethane prepolymer react to form polyurethane and generate carbon dioxide gas which forms many capillary passages for the transudation of ink. By grinding the dipped end a marking pen is obtained having a nib and an ink reservoir integral therewith.

Abstract: Strips of uncured glass wool, facing material, and backing material are intermittently fed from supply rolls into a multi-cavity molding press, and then into a trim press where molded tiles are severed from each other. A multi-cavity vacuum head transfers the tiles into stacks on a conveyor. When each stack has a certain number of tiles, the conveyor moves the stacks to a packaging station.

Abstract: A decorative high pressure laminate having registered color and embossing is produced by effecting a simultaneous embossing and laminating using a three-dimensional press plate acting against an overlay sheet containing high flow melamine resin and pigment beneath which lies a melamine resin impregnated print sheet and below that an underlay sheet containing high flow melamine resin and pigment of another color. During the pressing operation the resin and pigment in the overlay flow laterally from the high pressure areas to the low pressure areas with the result that the underlying print sheet is visible through the overlay sheet in the high pressure areas while the pigment in the overlay sheet in the low pressure areas masks the print sheet. In areas of even lower pressure the color from the underlay sheet strikes through to the surface to provide a third color.