Abstract: A roving laid flat of unitary metal, mineral or synthetic filaments is treated with a powder, whose grain size is equal to the diameter of the filaments, of a plastic material chosen either from the group of thermosetting polyers including the epoxides, the phenolics, the polyesters with terminal groups --COOH, the polyimides, the acrylics and the polyurethanes, or prepolymerized polyamides modified by diamines, polyolefins modified by maleic anhydride or acrylic acid, partially hydrolized EVA copolymers, the E-VA-maleic anhydride terpolymers and eva copolymers grafted by the acrylic radical, then the powder charged rovings are coated by a thermoplastic polymer, such as polyamides, copolyamides and linear polyesters, the material thus obtained being placed in a mold under pressure and at a temperature not exceeding 170.degree. C.

Abstract: Rigidized composite preforms are fabricated by first serving individual reinforcement strands with a thread of a thermoplastic material. After shaping the reinforcement strands into a desired geometry, the shaped strands are heated to melt the thermoplastic threads. By then cooling the shaped reinforcement strands, the thermoplastic material solidifies and acts as an adhesive or glue in holding the preform together in a rigid fashion. Such rigid preforms are particularly suitable for handling, storage and transportation to other locations and media prior to densification. Densification may be performed by conventional techniques to produce the final composite article. Pyrolysis of the matrices and subsequent densification of the matrix may be accomplished.

Abstract: Clamps mounted on a reciprocal frame grip a web of connected molded fibrous articles and move toward a cutter a distance equal to one article length, thereby presenting to the cutter the connecting portion between adjacent articles and also pulling the next portion of uncured fibrous material into the mold press for shaping and curing. After the cutting operation the clamps open and move toward the mold into position to again grip and feed the web toward the cutter. Connected rows of webs can also be handled by slitting the rows as they move toward the cutter. The articles, which can be quite deep compared to the thickness of the connecting portions between articles, are supported during travel and while stationary by support plates separate from the reciprocal frame. The various components which contact or cause movement or cycling of the apparatus can be adjusted to permit handling of articles and webs of different dimensions.

Abstract: Non-slip properties are imparted to molded plastic articles by adhering a layer of latex or a latex-impregnated sheet material onto the surface of the molded article. Preferably, the latex layer is applied prior to thermoset curing of the molded article and is adhered to the thermoset article during the curing process. The plastic may be reinforced, and the latex is preferably an acrylic latex impregnated into a sheet material such as cloth or paper.

Abstract: A method of making a bow limb which comprises the steps of wrapping impregnated fiberglass strands around a frame to create a fiberglass and resin blank or package. The wet blank or package is then placed in the mold to be shaped and cured. The package has a calculated predetermined number of fiberglass strands, and also a calculated predetermined volume and weight of plastic resin. The mold, has two parts, a male and female. The volume of the mold may be simultaneously thinned and widened in forming the mold in such a manner that the cross-sectional area is constant at any given point. The thickness of the limb can be varied in accordance with the depth of penetration of the male member of the mold into the female. A tail of the excess fiberglass and resin extends from both ends of the mold, and after the formed unit or paddle is first cured and then removed from the mold; these are removed with a saw cut.

Abstract: A continuous carbon fiber reinforced SiC composite is produced by a method which comprises impregnating continuous carbon fibers coated with a SiC or titanium compound with a slurry mixture of silicon or a silicon compound with a thermosetting resin or a high-carbon caking agent, molding the impregnated continuous carbon fibers in a prescribed shape to obtain a shaped impregnated article, then curing the shaped article, heating the shaped article to obtain a carbon fiber-carbon composite having SiC or titanium compound, further impregnating liquid Si into the composite and heating the impregnated composite.

Abstract: In a method of producing implants of bone replacement material from resin reinforced with carbon fiber at least the fibers in the parts of the surface which are to come into contact with the bone tissue are exposed by mechanical treatment. This provides for an improved unification of the bone with the implant. The fibers at the surface may be fibers of a fabric which is wrapped around a basic member shaped to conform to the desired implant.

Abstract: To provide the perfume carrier of an artificial flower both with a high absorption capacity and with high mechanical stability, a random-fiber fleece of rayon staple fibers is mechanically stabilized by needle punching and then compressed in a press of which all the forming surfaces are heated.

Abstract: A non-metallic leaf spring in which a unitary body member is made up of strands of glass fibers distributed in a matrix of polymerized epoxy resin. The spring is provided with end fittings and a mounting assembly intermediate the ends of the spring by which the spring can be mounted between suspended and unsuspended structures without causing stress concentrations at the non-metallic spring. The method and apparatus by which the spring is manufactured casues strands of fiber to be distributed throughout the spring at a substantially uniform density throughout the longitudinal length of the spring.

Abstract: A polyamino-bis-maleimide prepolymer solution obtained by the reaction of 1 mol of N,N'-4,4'-diphenyl methane-bis-maleimide with 0.25 to 0.4 mol of 4,4'-diaminodiphenyl methane in an alkyleneglycol monoalkyl ether as a solvent at elevated temperatures. This solution can be impregnated with a substrate to form a prepreg. The prepreg can be laminated to form heat resistant laminate.

Abstract: A ball batting aid consisting of a spherical ball made of an expandable elastomeric material having a finite length of braided rope secured thereto, the ball being formed so that there is no air pocket within the confines thereof. An enlargement is placed on one end of the rope located in the central portion of the ball and when the ball is formed, the elastomeric material is expanded into the space between the braids of the rope to effect a securement of the material to the rope.

Abstract: In the manufacture of a pipe part from fibre-reinforced thermosetting resin, such as a T-piece, preformed pipe parts made of fibre-reinforced thermosetting resin are placed on a mandrel defining the inside shape of the pipe part, the external surface of the mandrel being partially covered. The space between the mandrel and the inside of the pre-formed pipe parts is sealed and the parts of the pre-formed pipe parts adjacent to the uncovered part of the mandrel are chamfered on the outside. Synthetic resin impregnated fibres are then applied to the uncovered part of the mandrel and to at least the chamfered parts of the preformed pipe parts placed on the mandrel, until the pipe part has reached the desired final shape, after which it is cured and the mandrel is removed from the finished pipe part.

Abstract: A method and an apparatus for continuous shaping of carbon-fiber-reinforced plastic tubes, wherein a carbon fiber prepreg in tape form impregnated with a thermosetting resin is laminated on and around a mandrel, then the laminated carbon fiber prepreg tape on the mandrel is preheated, and the thus preheated laminate is pulled in and through a hot die together with the mandrel so as to subject the carbon fiber prepreg to gelling, curing and shaping into a predetermined carbon-fiber-reinforced plastic tube, the pulling operations being continuously carried out by alternate motion of first and second grasping mechanism in such a manner that the pulling force is generated in the second grasping mechanism, while the first grasping mechanism still retains its pulling force, and finally the gellation of the laminate is completed at the first half part of the hot die.

Abstract: A process for continuously molding a plate for an electrical printed circuit board wherein a resin containing uniformly distributed hollow microspheres having a specific gravity different from that of the resin is extruded into a vertically disposed moving double belt press maintained at a temperature which allows the extruded plate to harden almost completely. The plate exists the vertically disposed press maintaining a flexibility sufficient to be passed around a roller into a horizonal position where subsequent processing steps may be applied, such as lamination of reinforcing fiber and coating with a conductive material.

Abstract: In a filament winding technique, filaments are wound around a mandrel, and the mandrel remains in the structure and becomes part, normally a structural part, of the article. The mandrel may be any suitable rigid, light-weight material, but a foamed material such as a structural foam is thought to be most suitable. Metal inserts for attaching other components to the filament wound article can be moulded into the mandrel surface, and locked in place by the filament windings. According to a preferred aspect of the invention a motor vehicle suspension wishbone is made according to such filament winding method and the mandrel on which the filaments are wound remains in the structure.

Abstract: Fiber-reinforced materials are produced by a process in which a heat-stable thermoplastic aromatic polyether A which contains reactive groups, preferably nitrile groups and/or sulfur bridges and/or arylthio or alkylthio groups, if necessary together with a heat-stable thermoplastic polymer B which does not contain any reactive groups, is applied onto reinforcing fibers, the resulting semi-finished product is molded and, in the molding obtained, the plastic matrix is crosslinked so that the glass transition temperature increases and it becomes virtually insoluble.

Abstract: A process for the manufacture of glass fiber-reinforced polyester products is disclosed. A ready-to-mold resin and reinforcement composite is prepared using an initiator which has been microencapsulated in order to prevent initiator-induced cross-linking of the resin reactants. The initiator is released during the molding of the composite by rupture of the microcapsules due to internal vapor pressure developed at a preselected molding temperature. The encapsulation of the initiator provides improved homogeneity and increased flowability of the composites during molding, and enables the provision of molded polyester products having higher degrees of cure and more defect-free finish surfaces.

Abstract: A variable pitch multi-blade propeller suitable for use on a helicopter is constructed of a foam preform joined with a fibrous spar enclosed in resin-impregnated foils and fitted with a metal leading edge. Various components are assembled in a mold and the resins, then cured. The structure may further include a reinforcing yoke of carbon fiber fabrics preimpregnated with a polymerizable synthetic resin. The process may further include a heat treating step to effect polymerization.

Abstract: A diaphragm for loudspeakers and the like comprises a diaphragm base component formed of ceramics of a three-dimensional network structure so as to be light in weight, high in bending stiffness, easy to make and high in sound velocity. The diaphragm base component is sealed by a sealing material so as to be made air-permeable. This diaphragm is made by impregnating combustible foamed plastics material with a ceramic slurry, baking the ceramic impregnated foamed plastics to burn off the foamed plastics material, and the diaphragm base component sealing with the sealing material.

Abstract: A fiber reinforced plastic composite wheel and method of making it is disclosed. The wheel includes a rim and a disc, with the disc comprising reinforcing fibers oriented predominantly in a radially outwardly extending direction. The rim, in the preferred construction, has a plurality of radially disposed and substantially distinct layers. The inner and outermost layers have fibers that extend essentially in the same direction, with one or more middle layers having fibers extending in an opposite direction. Preferably, the inner and outer layers have directional fibers extending essentially parallel to the wheel axes.

Abstract: A method of molding a composite material comprising reinforcing fibres enclosed in a resin matrix. Layers of the resin impregnated fibres are laid-up in a suitably shaped die whereupon the laid-up layers are overlaid by a silicone rubber member which generally corresponds in shape with the die. Hydraulic pressure is exerted upon the silicone rubber member so that it urges the laid-up fibres into the configuration of the die. The whole molding apparatus is placed in an oven and its temperature is raised to that at which consolidation of the laid-up fibres occurs and the resin cures. The exerted hydraulic pressure is progressively reduced during heating as the silicone rubber member thermally expands so as to ensure that the pressure exerted by the silicone rubber member upon the laid-up fibres remains substantially constant.

Abstract: A process for the manufacture of glass fiber-reinforced polyester products is disclosed. A ready-to-mold resin and reinforcement composite is prepared using an initiator which has been microencapsulated in order to prevent initiator-induced cross-linking of the resin reactants. The initiator is released during the molding of the composite by rupture of the microcapsules due to internal vapor pressure developed at a preselected molding temperature. The encapsulation of the initiator provides improved homogeneity and increased flowability of the composites during molding, and enables the provision of molded polyester products having higher degrees of cure and more defect-free finish surfaces.

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: An oriented continuous strand mat of glass fiber filaments is formed by interleaved layers of generally circular or random loops and elongated elliptical loops having their longitudinal axes positioned in the direction of travel of an endless conveyor upon which the glass fibers are deployed to form a mat useable in a stampable glass fiber reinforced thermoplastic resin sheet having increased tensile strength in the length of the sheet. An elongated deflector plate having a planar deflecting surface whose length is aligned with the direction of conveyor travel, and whose face plane is generally perpendicular thereto receives pulled strands which have passed through an air flow nozzle and forms the strands into the elongated elliptical loops used to make the mat.

Abstract: A fabric reinforced composite having increased bond strength between impregnating resin and polyaramide reinforcing fabric and method for making the composite including using metal coated polyaramide fabric as the reinforcing material. The metal is deposited by a non-electrical method.

Abstract: In this process for forming an internal screw thread in a tube or link made from a composite carbon fiber based material coated with polymerized resin, the part of the tube or link comprising the screw thread is inserted in the body of the tube or the link and molded on a threaded mandrel. This part of the tube or link where the screw thread is to be formed is polymerized substantially completely and under pressure on the threaded mandrel so as to obtain a preform comprising a hard internally threaded portion extended by non polymerized fibers; an expandable mandrel is introduced into this preform; the preform is inserted inside a tube which is already polymerized or to be cured; and finally polymerization under pressure of the fibers is provided by heating and causing the mandrel to expand so as to bond them to the fibers of the tube.

Abstract: A process for producing a clutch facing which comprises the steps of: impregnating inorganic fibers with a thermosetting resin; causing rubber composition sheets to adhere to the resin-impregnated inorganic fibers, said sheets having been obtained by causing organic fibers to add to a rubber composition as a processing aid and forming the resulting material into sheets; forming a preform therefrom; and molding the preform under heat and pressure.

Abstract: A method of making a flat gasket comprising a non-woven mat having opposite faces, including the steps of impregnating the mat with a polymerizable liquid impregnating agent and applying to at least one part of at least one mat face a coating containing a polymerizable polymer material. The coating is applied to the impregnated mat prior to polymerization of the impregnating agent. The impregnating agent and the coating are simultaneously polymerized in one operation.

Abstract: The present invention is a method of making fiber reinforced composite articles using match molds to compact a partially hollow fiber/matrix lay-up. The method comprises wrapping the matrix and fiber reinforcement about a mandrel, removing the mandrel from the lay-up or chilling the wrapped mandrel allowing for easy removal of the mandrel resulting in a relatively stiff hollow lay-up. The lay-up is then placed in a mold and compacted and cured to form the desired composite article. Such a method provides an easy method to form such complex composite article shapes as I-beam, C-beam, etc.

Abstract: A method and apparatus for making a polymeric coated fabric layer is provided, the method comprising the steps of providing a fabric layer having warps and fills initially woven at a certain angle relative to each other, then changing the certain angle to another angle by stretching the fabric layer in one direction thereof whereby the fabric layer is in an altered condition thereof, disposing a liquid polymeric coating on at least one side of the fabric layer while the same is in the altered condition, doctoring the coating, further stretching the fabric layer in the one direction after the step of disposing the coating thereon, and drying the coating with a heating unit to at least a degree thereof that will hold the fabric layer in substantially the altered condition thereof, the step of doctoring the coating taking place after the step of further stretching the fabric layer and the step of further stretching the fabric layer taking place after the heating unit has dried the coating to at least a degree th

Abstract: In production of a wood-type golf club head having a fiber reinforced shell, a fiber reinforced plastic covering containing long fibers is molded into the shell by application of heat under pressure which enables the shell to fairly assume the complicated configuration of the club head, and use of long fibers assure uniformly oriented reinforcement which results in enhanced elastic impact at hitting balls.

Abstract: A fiber reinforced plastic leaf spring including a curved central section and a pair of end sections, each having a bushing to receive a connecting member. The spring is formed from a plurality of longitudinally extending substantially continuous strands of fibrous material impregnated with a cured thermosetting resin which are wound in a loop configuration around the bushings. The windings consist of a pair of generally parallel runs which extend between the bushings and are disposed in contiguous relation and the resin is cured to formed an integral structure. Each bushing includes a tubular section and at least one circumferentially extending rib that extends outwardly from the tubular section and is encapsulated in the fibrous windings. The ribs act to prevent delamination of the two runs along the neutral axis of the spring when the spring is subjected to load in service.

Abstract: A curing mold for curing glass fiber pipe insulation contains alternating positive and negative pressure zones and hot curing gases are introduced to the glass fibers during advancement through the positive pressure zones, and the curing gases are exhausted from elongated exhaust openings in the mold during advancement through the negative pressure zones, and the exhaust openings are cleaned without interrupting the advancement of the glass fibers through the curing mold.

Abstract: A flash free, compression molded object which includes an insert and is formed using only one mold plate is disclosed. Molding compound is trapped in a mold cavity between the insert and mold plate. An extrusion vent allows excess molding compound and curing gases to escape from the mold cavity. Systems for forming a pin hole within the molded object and removing the molded object from the mold plate are also disclosed.

Abstract: The invention provides a method for preparing a SiC whisker-reinforced composite material. A matrix material such as a metal, an alloy or a plastic is introduced into a fibrous base consisting of a SiC whisker sponge-like cake. The resultant structure is compressed into a desired shape as needed. The fibrous base is prepared by heating a mixture of silica gel or ashed rice hulls with a furnace carbon black and an additional amount of NaCl as a space forming agent for forming spaces conducive to whisker growth.

Abstract: A method of manufacturing a friction article wherein a fiber material (14) having a continuous and substantially uniform three dimensional matrix which is filled with a slurry (24) made up of fillers, friction modifiers, a reinforcing material and a liquid binder. The filled fiber material is conveyed to a dryer (32) where the volatile solution is evaporated leaving the fillers, friction modifiers, reinforcing material and binder. The filled fiber material (14) is thereafter placed in an oven (50) where a compressive force is applied thereto while the binder is cured to define a second matrix which holds the fillers, friction modifiers, and reinforcing material in the three dimensional matrix.

Abstract: Insulation board capable of bearing a load without significant loss of insulating capacity due to compression, produced by a method wherein the board is made in compliance with specified conditions of time, temperature and pressure.

Abstract: The method of the present invention produces a tape of high performance reinforcing fibers having improved alignment between the fibers and improved maintenance of that alignment in processing and molding applications. The method involves contacting one or more of the continuous high performance reinforcing fibers with a polymer impregnated mat. The polymer is compatible with any polymeric material used in the subsequent processing or molding applications. The contacting is performed with the high performance fibers under tension, and the tension is removed when the fibers are properly aligned into a tape in contact with the impregnated mat. The tape material can be used with various molding compounds such as sheet molding compounds and high reinforcement content molding compounds and thermoplastic molding materials wherein the molding compound is contacted with the tape product.

Abstract: The object of the invention are new thermoset polymers and prepolymers, a process for their preparation, and their uses. The new thermoset prepolymers consist, at least in part, of the polycondensation products of one or more pyridine derivatives containing at least two activated methyl groups with one or more aromatic monoaldehydes containing at least one hydroxyl group. These prepolymers are used to prepare composite materials, in particular laminates, that can be used at high temperatures.

Abstract: A composite which has a high flexural strength to density ratio and which is resistant to strength loss incident to exposure to water, is formed by reinforcing unsaturated thermosetting resin with glass fibers sized with selected maleic anhydride adduct of polybutadiene utilized in critical amounts.

Abstract: A process for the manufacture of glass fiber-reinforced polyester products is disclosed. A ready-to-mold resin and reinforcement composite is prepared using an initiator which has been microencapsulated in order to prevent initiator-induced cross-linking of the resin reactants. The initiator is released during the molding of the composite by rupture of the microcapsules due to internal vapor pressure developed at a preselected molding temperature. The encapsulation of the initiator provides improved homogeneity and increased flowability of the composites during molding, and enables the provision of molded polyester products having higher degrees of cure and more defect-free finish surfaces.

Abstract: A process for producing a composite plastic pipe, which comprises producing a thermoplastic resin pipe (I) by an extruder, covering the surface of the pipe (I) uniformly with a continuous fibrous reinforcing material (II) impregnated with a thermosetting resin in its axial direction by a draw molding method, helically winding a continuous fibrous reinforcing material (III) impregnated or not impregnated with a thermosetting resin uniformly on the layer of the resin fibrous reinforcing material (II) by a filament winding method, thereafter curing the thermosetting resin by irradiation of ultraviolet light and coating a thermoplastic resin (IV) on the resulting product within a crosshead die in an extruder.

Abstract: The inventive method is used to make 3-Dimensional reinforced and flanged parts from filaments which are braided or wound flat (parallel to the surface of a mandrel).The method comprises the steps of:depositing a first layer of impregnated reinforcements on a mandrel parallel to the surface of the mandrel;placing separators on a portion of said first layer;depositing a second layer of impregnated reinforcements over the separators and said first layer;cutting said layers at the separators;removing said layers from the mandrel;parting the layers along said separators;removing said separators from said reinforcements;placing said cut and partially separated layers in a mold;conforming the layers to the shape of the mold;curing said impregnated reinforcements into a composite part; andremoving said composite part from said mold.

Abstract: A forming tool made from resins and fillers for the cold forming of sheet metal and especially suitable for forming short runs of sheet metal parts with drop hammers, hydraulic presses or mechanical crank presses, the filler being a mixture of iron filled resin and an aggregate; the aggregate being a lightweight by-product of the steel making process.

Abstract: A reinforced protective housing that may be utilized for protection of electrical contacts; such housing is reinforced with cured resin-coated open mesh glass cloth. Electrical contacts are incorporated into the glass cloth reinforced plastic body to form a unitary electrical connector component. A method of manufacturing cured resin-coated open mesh glass cloth reinforced molded plastic electrical connectors.

Abstract: A process for the application of an adhesive activated emulsion to a polyester yarn. More specifically the process involves applying an adhesive during drawing stage of the polyester yarn. The adhesive is applied to an essentially fully drawn yarn.

Abstract: A process for preparing a thermoplastic poly(imidesulfone) is disclosed. This resulting material has thermoplastic properties which are generally associated with polysulfones but not polyimides, and solvent resistant which is generally associated with polyimides but not polysulfones. This system is processable in the 250.degree.-350.degree. C. range for molding, adhesive and laminating applications. This unique thermoplastic poly(imidesulfone) is obtained by incorporating an aromatic sulfone moiety into the backbone of an aromatic linear polyimide by dissolving a quantity of a 3,3',4,4'-benzophenonetetracarboxylic dianhydride (BTDA) in a solution of 3,3'-diaminodiphenylsulfone and bis(2-methoxyethyl)ether, precipitating the reactant product in water, filtering and drying the recovered poly(amide-acid sulfone) and converting it to the poly(imidesulfone) by heating.

Abstract: A method of forming perforations in composite laminates by impregnating the material with a modified epoxy resin by means of hot melt or solvent methods. The resin is then allowed to dry. The epoxy impregnated material is then warmed to around 165.degree. F. and forced by a resilient pressure pad over a tool having a plurality of upstanding studs or pins. While in position on the pin tool, the laminate is then partially cured by combined heat and pressure to minimize resin flow while retaining the ability to be formed to a final contour in a contoured curing fixture after removal from the pin tool. Controlled partial cure and selected low flow resin systems prevent resin flow into the formed apertures formed by the pin tool during final resin cure.

Abstract: A reinforced thermoplastic resin composition comprising a thermoplastic resin, a fibrous, flaky or powdery inorganic reinforcing material, and an uncured, thermally curable resin, such as a thermosetting resin, applied to the surfaces of the inorganic reinforcing material. Molding of this composition by injection molding or the like yields a molded product in which the thermally curable resin has been cured by the heat during the molding to provide a strong chemical bond between the inorganic reinforcing material and the thermoplastic resin. The molded product thus obtained possesses more strength and/or elongation than the conventional thermoplastic resin product.

Abstract: A cylinder head gasket having at least one plate of soft material and at least one combustion chamber opening, said soft material including predominantly inorganic fibers and/or filling materials connected by binding means and including free OH groups, the soft material is mixed with a first impregnating material comprising a polysiloxane containing reactive hydrogen groups for reaction with the free OH groups of the fibers or filling materials and a second impregnating material which consists of a second polysiloxane of a higher degree of polymerization than the first polysiloxane and which polymerizes with itself as well as with the reactive hydrogen groups of the first polysiloxane, said second polysiloxane forming a stable siloxane structure having more branches than the first polysiloxane.