Abstract: A fiber-reinforced composite ballistic panel is formed continuously. A pultrusion process may be used to form the ballistic panel in such a continuous manner.

Abstract: The present invention concerns an extrusion formed reticulated web, mesh or netting including reticulated hook fasteners for use with hook and loop fasteners the polymer netting comprising two sets of strands at angles to each other. The first set of strands are a plurality of oriented (molecular orientation created by stretching) strands extending in a first direction and are generally mutually parallel and linear. The second set of strands are a plurality of substantially parallel strands attached only to a first face of the first set of oriented strands. The first set of oriented strands occupy a first planar cross-sectional area in the thickness direction of the formed netting. Said second set of oriented strands occupy a second planar cross-sectional area in the thickness direction of the formed netting. Preferably, these first and second planar cross-sectional areas are substantially mutually exclusive and are abutting.

Abstract: Processes are provided for formation of complex shapes by embossing of a sheet of flexible graphite material. In one approach, a sheet (26) of material is provided with a variable resin concentration across a selected dimension of the sheet, and the position of the variable which will result in thinner areas in the embossed articles. In a second approach, recesses are provided in the embossing rollers (30 and/or 32) to accomodate material flow during embossing. These recesses result in protrusions formed on the articles, which protrusions must then be removed in a machining operation.

Abstract: A method of making a fastener product having discrete regions of fastener element stems extending from a strip-form base includes providing a gap formed along a peripheral surface of a rotating mold roll, the mold roll having a plurality of cavities exposed about the peripheral surface. A sleeve is introduced to the gap. The sleeve is positioned about the mold roll and covers selected cavities. Molten resin is introduced to the gap such that the resin forms at least a part of the strip-form base of the product at the peripheral mold roll surface and at least partially fills a plurality of the cavities to form fastener element stems as projections extending from the strip-form base, while the resin remains blocked from said selected ones by the sleeve. The resin is solidified and stripped from the peripheral surface of the mold roll by pulling the projections from their respective cavities.

Abstract: A method for forming a unitary polymeric projection or fastener comprising a thin, strong flexible backing, and a multiplicity of thin spaced hook members projecting from the upper surface of the unitary backing the method generally including extruding a thermoplastic resin through a die plate which die plate is shaped to form a base layer and spaced ridges, ribs or hook elements projecting above a surface of the base layer. When the die forms the spaced ridges or ribs the cross sectional shape of the hook members are formed by the die plate while the initial hook member thickness is formed by transversely cutting the ridges at spaced locations along their lengths to form discrete cut portions of the ridges. Subsequently longitudinal stretching of the backing layer (in the direction of the ridges on the machine direction) separates these cut portions of the ridges, which cut portion then form spaced apart hook members.

Abstract: A process for preparing perfume film chips comprising inclusions of perfume particles.

Abstract: The present invention provides a method for forming preferably a unitary polymeric hook fastener comprising a flexible backing, and a multiplicity of spaced hook members projecting from the upper surface of the unitary backing wherein each hook member comprises a multiplicity of hook head elements projecting in substantially the same direction. The hook members each comprise a stem portion attached at one end to the backing, and a head portion at the end of the stem portion opposite the backing. The head portion can also extend from a side of a stem portion or be omitted entirely to form alternative projections which can be other forms than a hook member. The head portion preferably projects past the stem portion on at least one of two opposite sides. At least the hook head portions have two or more hook head elements on at least one of the two opposing sides of the stem.

Abstract: A method of forming a joint (32) between two plastics extrusions (10) is disclosed which comprises mitring the extrusions (10) so that they form the desired angle to one another, removing part of the rear face of each extrusion (10) placing the mitred extrusions in a mould and injecting a resin material whereby to bond the extrusions (10) to one another and produce the desired joint (32) configuration. Because the front surface (24) of the joint in accordance with the invention is entirely made up from the original extrusion, there are no problems with raised sight-lines, colour differentials, surface differences, or colour matching. Moreover, the method of the invention allows a corner to be produced which has a clean right angled rather than radiused inner portion.

Abstract: Process and apparatus for air forming an article having a plurality of superimposed fibrous layers. The layers are formed in substantially discrete forming chambers by depositing fibrous material on a forming surface which moves along an arcuate path through the chambers. A first layer is air-formed on the forming surface as the surface moves through the first forming chamber and a second layer is air-formed over the first layer as the surface moves through the second forming chamber.

Abstract: Disclosed is a continuous line process for making a pre-formed object having a plurality of surfaces comprising the steps of: (1) providing a sol phase of the composition comprising a solvent and a gelling agent having a sol-gel transition point between about the melting point of the solvent and about the boiling point of the solvent; (2) forming surfaces of the sol phase composition by passing through a surface forming system, the surface forming system pressing the sol phase composition between a plurality of liners; (3) cooling the sol phase composition into a gel phase; and (4) cutting the gel phase composition; wherein the pre-formed object is free of a supporting substrate.

Abstract: The present invention provides a fastener strip having magnetically attractable particles which are not located across the entire volume of the strip, but rather are incorporated in a discrete, distinct area of the strip. The fastener strip has a base and many hook pieces which rise from a fastening surface of the base. One embodiment has a magnetically attractable body in a row which rises from the surface of the base and is located along a substantially center line of the fastener strip. The magnetically attractable particles are incorporated in the magnetically attractable body and a part of the base located below the magnetically attractable body, and the magnetically attractable particles are not dispersed across the whole area of the base. A method of manufacturing such a strip is also described here.

Abstract: A multi-layer printable thermoplastic film consisting of at least a fluoride polymer film having laminated thereto a polycarbonate film. The printable film is preformed (vacuum molding or thermoforming) and then inserted into a mold which has the configuration of the preformed printable film. A base layer of a thermoplastic such as a polycarbonate resin is injection molded to the exposed surface of the preformed printable film. The molded structure has exterior automotive applications such as lens, etc.

Abstract: A unitary fastener of a thermoplastic resin comprising a base film layer having generally parallel upper and lower major surfaces, arranged in a first direction the base film layer being oriented at least in the first direction. The backing layer having on at least one surface separated surface elements extending at an angle to said first direction. The invention is also related to a method of forming a unitary fastener. The method includes the steps of extruding a thermoplastic resin in a machine direction through a die plate having a continuous base portion cavity and one or more rib cavities extending from the base portion cavity, forming a strip having a base layer and continuous rib. This scoring or cutting the ribs and at least a surface layer of the film structure forms predetermined separable elements. This inelastically stretching the strip to separated projections and the separated separable surface elements across the strip.

Abstract: Method of forming a fiber web (210) intended for use in absorbent products, such as sanitary towels, by air-laying fibers. Separate air flows containing fibers are fed to a number n of different mat-forming wheels (160, 170, 180), where n is a whole number which is at least 2. Separate web layers (161, 171, 181) are formed on each mat-forming wheel. The fiber web (210) is formed by virtue of said web layers being combined downstream of the mat-forming wheels to form a common fiber web which is imparted very great manufacturing accuracy by virtue of the manufacturing method. The manufacturing speed and thus the web speed can be very high, and the desired manufacturing accuracy at the web speed concerned is achieved by selecting a sufficiently great number n of mat-forming wheels. The invention also relates to a fiber web manufactured according to the method.

Abstract: A method of making a fastener product having discrete regions of fastener element stems extending from a strip-form base includes providing a gap formed along a peripheral surface of a rotating mold roll, the mold roll having a plurality of cavities exposed about the peripheral surface. A sleeve is introduced to the gap. The sleeve is positioned about the mold roll and covers selected cavities. Molten resin is introduced to the gap such that the resin forms at least a part of the strip-form base of the product at the peripheral mold roll surface and at least partially fills a plurality of the cavities to form fastener element stems as projections extending from the strip-form base, while the resin remains blocked from said selected ones by the sleeve. The resin is solidified and stripped from the peripheral surface of the mold roll by pulling the projections from their respective cavities.

Abstract: A method for forming a unitary polymeric projection or fastener comprising a base layer, and a multiplicity of spaced projections or hook members projecting from the upper surface of the unitary base layer the method generally including extruding of forming a thermoplastic resin through a die plate or mold. A die plate, if used, is shaped to form a base layer and spaced ridges, projecting above a surface of the base layer. When the die forms the spaced ridges or ribs the cross sectional shape of the projections are formed by the die plate. The ridges are then cut at spaced locations along their lengths to form discrete cut portions of the ridges. The cut portions are then heat treated resulting in shrinkage of at least a portion of at least the cut portion thickness by from 5 to 90 percent, preferably 30 to 90 percent thereby forming discrete upstanding projections.

Abstract: A method of producing a polymer insulator and an end processing apparatus utilized for the method. The insulator has a core, an overcoat member arranged on the core, and a fitting member for securing the core at its both ends, wherein the core and the fitting member are secured under pressure at both ends of the core by contacting a ring-shaped protrusion portion arranged at both ends of the overcoat member to an open inner end of the fitting member. The method includes the steps of: forming the overcoat member on the core; forming the ring-shaped protrusion portion integrally with the overcoat member by processing an end portion of the overcoat member, and securing the fitting member.

Abstract: A zipper tape is provided which can freely be used regardless of whether the zipper tape is made from a polypropylene-based resin or a polyethylene-based resin and also on which letters can be printed or any color can be given thereto. A method of producing the zipper tape with high productivity by means of extruding male strips and female strips in rows in a batch is provided. The zipper tape with the mating section formed thereon has a three-layered structure. The male strips and female strip for forming a mating section together are extruded from a miscellaneous extrusion molding machine onto a surface of the thermally fused film for forming a mating section in rows in the state where adjoining male and female strips form pairs respectively and are thermally fused and bonded to the base tape.

Abstract: A method and apparatus for cutting a puff extrudate utilizing a blade that passes through the extrudate while the extrudate is in a viscous melt stage. The present invention utilizes a tube to facilitate production of a curly puff extrudate. A gap is provided in between the tube and the extruder die to allow a blade to access the extrudate as it exits an orifice in the die. The blade accesses the extrudate at the viscous melt stage, before the extrudate has cooled and hardened. The blade nicks the extrudate, as opposed to completely cutting it, which allows the extrudate to remain connected throughout processing such as curling in the containment tube. The gap also allows steam to be vented form the extrudate as it exits the orifice in the die. The nicked extrudate separates when fried or baked.

Abstract: Molding material consisting of resin coated reinforcing fibers in a molten mass of resin and fibers is prepared at a molding site for controlled supply to a molding machine. A conveying device, such as a pair of pinch rollers, serves to pull fibers from supply spools through guide orifices of a coating die having a chamber within which the fiber is coated with molten resin. Further impregnation of the fibers with resin takes place in the conveying device, which also develops pressure on its output side serving to push the mass of hot resin and fiber into a receiving device for movement to a molding machine. The receiving device may be the feed screw for an injection molding machine or simply a plate movable to and from a compression molding machine. The fibers may be cut into predetermined lengths by a cutting device positioned downstream of the aforesaid conveying device.

Abstract: A medical tubing is disclosed which includes a first material extending between proximal and distal ends of the tubing and which defines a lumen of the tubing. The tubing also includes a second material extending between at least portion of the distance between the proximal and distal ends of the tubing and that is embedded in the first material. The second material is fractured. The first material is flexible and the second material is relatively rigid and brittle and the two materials combined to provide a medical tubing that exhibits strain softening behavior.

Abstract: A method of fabricating discrete risers for shelving units includes the step of providing a plurality of openable and closable mold segments arranged end to end along a continuous path, and circulating the plurality of mold segments through multiple revolutions of the continuous path such that the mold segments are closed while traveling along a molding section of the continuous path. A molten stream of plastic is continuously extruded at an upstream end of the molding section and into mold cavities of the closed or closing mold segments. A pressure differential is applied to the mold cavities of the closed mold segments to conform the molten stream of plastic to the mold cavities. A continuous train of interconnected risers is ejected at a downstream end of the molding section. Discrete risers are separated from the continuous train.

Abstract: An apparatus and method for ultrasonically forming a surgical suture tip from a length of unfinished surgical suture material. The apparatus includes a first tipping die having a first face for contacting a portion of the length of unfinished surgical suture material. A second tipping die having a second face is also provided. The first and second die also having extending therefrom a first member and a second member. The first and second dies cooperate with the first and second members to form a length of suture. At least one mechanical actuator is provided for moving the first face of the first tipping die and the third face of the first member toward the second face of the second tipping die and the fourth face of the second member. A second actuator vibrates at least one of the first and second tipping dies at an ultrasonic frequency of about 15 KHz to about 70 KHz.

Abstract: An automotive extrusion-molded product such as a trim, weather strip, and window molding which is used at a vehicle body opening such as an automotive door, trunk, and window of an automobile comprises a core material (2) having a U shape in the cross section which is made of a hard synthetic resin, said core material having cut portions (7, 8) with various shapes and extending in the lengthwise direction and a coating body (3) made of a soft synthetic resin, which is adhered to the core material so as to cover the core material. The coating body (3) is provided with a pushed-in portion (5) which is formed integrally with the coating body and extends downward beyond the end portion (4, 4) of the core material so as to be able to be pushed in toward an inner peripheral surface (14) having a U shape in the cross section of the core material.

Abstract: Methods and apparatus for forming continuous lengths of material with non-uniform cross-sections are disclosed. In accordance with one aspect of the present invention, a method for forming a continuous length of material that is of a substantially non-constant cross-section includes providing the material to a single shaping wheel. The material is in a first state, and the single shaping wheel includes a template that is arranged to form a three-dimensional shape using the material. The method also includes shaping the material to form an extended strip from the material, as well as at least one three-dimensional shape in the extended strip. The extended strip and the three-dimensional shape being formed using substantially only the single shaping wheel. In one embodiment, the method includes cooling the extended strip by cooling the material from a molten state to a solid state.

Abstract: A method and apparatus for manufacturing a rubber sheet containing short fibers. The method includes the steps of: mixing short fibers in a flowable rubber matrix; forming the flowable rubber matrix with the fibers therein into a cylindrical shape with a circumferential extent; separating a portion of the circumferential extent from the cylindrical shape, and forming the cylindrical shape with the portion separated into a sheet form.

Abstract: A method for making a hockey stick shaft by a double pressing process, and an apparatus for making the same. The double pressing process consists of pulling resin soaked rovings through heated mold cavities. A core is inserted between upper and lower rovings, the press is closed, and upper and lower laminates are molded on simultaneously, using heat and pressure. The hockey stick shaft made therefrom has two opposite surfaces, each of the surfaces being provided with a fiberglass roving reinforcement along each opposite edge and a graphite roving reinforcement fiber between the two fiberglass roving means.

Abstract: A skin layer for covering a dash panel structure in overlying relation to an air bag cushion assembly. The skin layer is of a multi-layered construction including a top layer of virgin polymeric material forming a show surface of controlled predefined color across the vehicle dash panel and an underlying layer of regrind material formed from the scraps of material generated during molding and trimming of the dash panel covers. A tear seam may be scored across the underside of the skin extending into the underlying layer of recycled material in a desired break-out pattern for the air bag cushion. The skin layer may be disposed across an underlying layer of foam which in turn is disposed across a supporting panel structure.

Abstract: The present invention relates to the art of continuous forming of elongated strip-like products made of thermoplastic material, and more specifically to apparatus and method to forming said thermoplastic material over a substantial portion of the circumference of a forming roll. The present invention is specifically related to the art of forming agricultural products, and especially for the production of drip irrigation strip which may be used for installing in the inner side of a tube or to be folded to form an irrigation tube.

Abstract: An integral molded surface fastener is provided having minute and peculiar engaging elements, with which a desired plasticity and tearing strength of the flat substrate are secured. The molded surface fastener may be formed together with the substrate by continuous molding where the engaging elements are each comprised of a single column portion having a substantially cross-shaped section provided by intersection of a first column portion and a second column portion and rectangular thin plate-like engaging heads extended in the shape of wings in opposite directions along the width direction of the first column portion intersecting the second column portion around a top end of the column portion, and having substantially the same width dimension as the width dimension of a top end of the second column portion.

Abstract: A catheter includes an elongated tubular member having a lumen extending through the elongated tubular member. The elongated tubular member also has an outer surface, a distal end and at least one opening. The opening extends between the inner and outer surfaces, provides communication between the outer surface and the lumen and includes at least two straight edges extending parallel to the lumen of the tubular member.

Abstract: An epidural catheter with a soft tip is formed by extruding a two-layer tube where the inner layer is stiffer than the outer layer. The inner layer is then removed, such as by machining, from a short length at the tip, which is subsequently end-formed closed and a side opening cut into it.

Abstract: A method to produce shaped multi-layer plates having super-imposed layers includes individually extruding raw materials comprising powder, granules, or crystals, in liquid form, to form a plurality of separate layers, each layer being mono-component or multi-component, superimposing the separate layers, co-extruding the superimposed layers through a co-extrusion head with plane lips to form a continuous flat multi-layer plate with a plane surface, subjecting the flat multi-layer plate emerging from the co-extrusion head to a calendering pass to provide thermal, chemical and dimensional stabilization, subjecting the flat continuous multi-layer plate emerging from the calendering pass to a pass of thermal adjustment and shaping, and cooling and shearing to size the shaped multi-layer plate emerging from the pass of thermal adjustment and shaping so as to obtain shaped multi-layer plate of the desired length.

Abstract: The present invention provides a fastener strip having magnetically attractable particles which are not located across the entire volume of the strip, but rather are incorporated in a discrete, distinct area of the strip. The fastener strip has a base and many hook pieces which rise from a fastening surface of the base. One embodiment has a magnetically attractable body in a row which rises from the surface of the base and is located along a substantially center line of the fastener strip. The magnetically attractable particles are incorporated in the magnetically attractable body and a part of the base located below the magnetically attractable body, and the magnetically attractable particles are not dispersed across the whole area of the base. A method of manufacturing such a strip is also described here.

Abstract: The invention relates to a process for the production of cellulosic fibers from solutions of cellulose in an aqueous tertiary amine oxide whereby the extruded fibers are led through a precipitating bath and cut and the cut fibers are passed through a series of water baths in the form of a fleece and then dried, whereby the wash baths are connected to each other and fresh washing liquor is applied to the last wash bath and led in countercurrent with the transportation direction of the fibre fleece to the first wash bath. The process in accordance with the invention is characterised in that the pH value of each of these wash baths is maintained higher than 8.5.

Abstract: The present invention provides a process for the production of a transparent flat film from thermoplastic polyurethane (TPU) by introduction of the thermoplastic polyurethane between sheets of a higher-melting material. The transparent flat film may find use in optical applications.

Abstract: The decurl apparatus comprising: heating means for subjecting an image recording carrier web to a heating treatment at a constant temperature exceeding the glass transition temperature of a support for a constant time period; and cooling means for cooling the image recording carrier web after heated, to the glass transition temperature or lower, while keeping it in a predetermined shape. The heating means includes: a heating roller to be induction-heated; and holding rollers to be arranged at arbitrary angular positions with respect to the outer circumference of the heating roller. As a result, the image recording carrier web can be reliably decurled with the simple construction but without being influenced by the transfer velocity or the like.

Abstract: A method of manufacturing a microdialysis catheter, comprises the steps of extruding a flexible material to form an elongate catheter body having a substantially cylindrical outer surface and a plurality of continuous internal channels extending in the longitudinal direction of said catheter body; sealing a free end of said catheter body; providing in said surface at a distance from said free end an opening extending into said catheter body to communicate with a portion of a first of said channels; providing communication between said first channel and a second of said channels at a distance from said free end shorter that said distance; and covering said opening by a microdialysis membrane.

Abstract: A continuous process for manufacturing decorative panels includes the steps of forming a first continuous fiber reinforced resin layer, laying a continuous decorated sheet on the first fiber reinforced resin layer, forming a second continuous fiber reinforced resin layer on the continuous decorated sheet, eliminating a substratum of the decorated sheet so that the first and second fiber reinforced resin layers can join one another to form a continuous consolidated strip of fiber reinforced resin with an image suspended therein, curing the continuous consolidated strip, and cutting a panel from the continuous consolidated strip. The first fiber reinforced resin layer is preferably at least partially cured in a first curing step before the second fiber reinforced resin layer is formed.

Abstract: An apparatus and related methods for making test specimens. The apparatus transforms a first length of a material, extruded through a die of an extruder in accordance with a predetermined set of extrusion parameters, into a second length of material useable as at least one test specimen for evaluating material properties of the material extruded according to the predetermined set of extrusion parameters. The apparatus includes a transitioning plate having an orifice defining an input opening and an output opening, the input opening having a predetermined profile area that corresponds to a profile area of an orifice of the die, the input opening for receiving material extruded through the die orifice, the output opening having a predetermined profile area corresponding to that of the at least one test specimen.

Abstract: A tampon for feminine hygiene or medical purposes comprising a nonwoven cover having at least one, outwardly directed, smooth surface and substantially enclosing a liquid absorbing core wherein the nonwoven cover comprises at least partly thermoplastic, heat-sealable fibers and pressed to the final shape of the tampon. Before the tampon blank is covered with the nonwoven covering web, said web was subject to the use of heat and pressure during the manufacturing of the tampon as to smooth out at least the outer surface of the nonwoven covering web, whilst maintaining the structure of the nonwoven covering web and the absorbency of the tampon. Thereby, it is achieved that the tampon can also be more easily and more comfortably introduced into and withdrawn from a body cavity before and after the days of stronger menstruation or at the occurance of only less vaginal exudation as garment protection.

Abstract: A method of producing a breathable film which comprises the steps of: (a) producing an inorganic filler by treating particles of an inorganic particulate material comprising an alkaline earth metal carbonate compound by reaction with a hydrophobising surface treatment agent comprising one or more aliphatic carboxylic acids having at least 10 chain carbon atoms to produce a hydrophobic coating on the particles under conditions such that the inorganic filler produced has a total surface moisture level comprising moisture adsorbed on the particles and trapped within the hydrophobic coating thereon of not greater than 0.1% by weight based on the dry weight of the inorganic particulate material; (b) producing a filled thermoplastic composition by mixing the inorganic filler produced in step (a) with a heated thermoplastic polymer; and (c) shaping the composition produced in step (b) by heat processing to form a film product.

Abstract: Continuously connected fastener stock and a method of making same. In one embodiment, the method involves providing a rotating molding wheel, the wheel being provided with a peripheral impression comprising a pair of peripherally-extending side members interconnected by a plurality of cross-links. Molten plastic is extruded into the peripheral impression of the wheel, with a layer of controlled film overlying the peripheral impression. The molten plastic is then allowed to solidify. A knife in substantially elliptical contact with the peripheral impression is then used to skive excess plastic from the rotating molding wheel. The knife is provided with a pair of cut-out portions along its bottom edge, each cut-out portion being aligned with one of the peripherally-extending side members so as to augment the transverse cross-sectional size thereof. The continuously connected fastener stock thus formed is then removed from the rotating molding wheel.

Abstract: A method is provided for making ligneous material boards into an endless board strand with a continuously operating press. The press includes two flexible endless steel belts which take the press material between them and carry it through the press. The steel belts thrust with friction-reducing elements against heated press plates of the press table and press ram and a cooling system that follows. The cooling system is configured as a double-belt holding apparatus with an applicable holding pressure up to a maximum of 0 to 0.05 N/mm2. A diagonal sawing apparatus, which is disposed directly behind the continuously operating press and ahead of the cooling system, divides the board strand into single boards. Several rows of coolant spray nozzles disposed on the backs of the holding belts making contact with the single boards.

Abstract: Disclosed is a process of forming a prepreg material having substantially no voids. According to the process of the invention, the reinforcing material is heated to a temperature above the temperature of the impregnating resin. The prepreg formed has substantially no voids and does not require lengthy consolidation when formed into useful articles.

Abstract: The object of the present invention is to provide a method for manufacturing a product of thermoplastic resin and/or thermoplastic elastomer with materials of high recycle capability, preventing the productivity drop and the cost increase as well as the damage caused by the contact between semi-finished products and a drawing machine. A plurality of semi-finished moles and a drawing element are molded integrally by an extruder. The semi-finished moles are separated from the drawing element by cutting. The semi-finished moles separated from the drawing element are cut in accordance with a given length to produce a mole.

Abstract: Continuously connected fastener stock and a method of making same. The method, in one embodiment involves providing a rotating molding wheel, the wheel being provided with a peripheral impression comprising a pair of peripherally-extending side members interconnected by a plurality of cross-links. Molten plastic is extruded into the peripheral impression of the wheel, with a layer of controlled film overlying the peripheral impression. The molten plastic is then allowed to solidify. A knife in substantially elliptical contact with the peripheral impression is then used to skive excess plastic from the rotating molding wheel. The knife is provided with a pair of cut-out portions along its bottom edge, each cut-out portion being aligned with one of the peripherally-extending side members so as to augment the transverse cross-sectional size thereof. The continuously connected fastener stock thus formed is then removed from the rotating molding wheel.

Abstract: Continuously connected fastener stock and a method of making same. In one embodiment, the method involves providing a rotating molding wheel, the wheel being provided with a peripheral impression comprising a pair of peripherally-extending side members interconnected by a plurality of cross-links. Molten plastic is extruded into the peripheral impression of the wheel, with a layer of controlled film overlying the peripheral impression. The molten plastic is then allowed to solidify. A knife in substantially elliptical contact with the peripheral impression is then used to skive excess plastic from the rotating molding wheel. The knife is provided with a pair of cut-out portions along its bottom edge, each cut-out portion being aligned with one of the peripherally extending side members so as to augment the transverse cross-sectional size thereof. The continuously connected fastener stock thus formed is then removed from the rotating molding wheel.

Abstract: A rebar forming apparatus includes a malleable material supply station for continuously supplying a malleable planar material and a malleable material forming station for forming the malleable material into first and second corresponding shell portions and related rebar products. The apparatus also includes a core pultrusion station and a cladding forming station for respectively forming core and cladding layers. A shell forming station is positioned downstream of the core and cladding forming stations which unites the first and second shell portions to form an outer shell with the core and cladding layers contained therein. The rebar product includes shell portions which are matably configured to form a disposable outer shell over the core and cladding layers. Related reinforcing composite product forming methods also include the use of a removable outer shell.

Abstract: A method of manufacturing a sacrificial limb for a deck plank provides a deck plank that is comprised of a wood replacement material. The deck plank has a tongue that is adapted to fit with a groove of an adjacent deck plank. A channel is cut in the tongue of the deck plank. The channel is adapted to induce the tongue to fracture when expansion of the wood replacement material causes sufficient pressure between the tongue and the groove of the adjacent deck plank. As a result, expansion and contraction of the deck plank material preferably does not cause the deck to buckle.