Abstract: A method and apparatus in which a granular adsorbent, absorbent, chemisorptive, or catalytic material, particularly activated carbon is intermixed with (a) meltable polymer(s), and that the resulting mixture is heated under pressure and pressed into a molded piece (2). We propose to heat the mixture under pressure in a connecting part for a respirator or fan filter unit or in a connecting part (1) for an adapter for a respirator or fan filter unit, thereby positively and/or non-positively compacting it with said connecting part, and to make the connection between said connecting part (1) and said compacted mixture gastight.

Abstract: An earplug (10) that includes a soft foam body (12) and a stiffener (14) in the body, is produced by a method that has minimum steps and that results in an earplug of attractive design and that uses a minimum of material. One method includes molding an earplug body in a body cavity (52) while a mandrel (56) lies in the body cavity. After the foam material in the body cavity has at least partially solidified, the mandrel is removed, leaving an empty stiffener cavity (60) in the foam body (12). With the body remaining in the body mold (54), flowable stiffener material (14A) is poured into the stiffener cavity of the body and allowed to solidify, to produce an earplug with a molded-in stiffener (14). Another method, results in an earplug (90) with a stem (95) having a rearwardly-projecting stem portion (96). This method includes molding a stem rear portion (96) in a stiffener cavity (110) while allowing stiffener material to project forward of the rear portion to form a stem free front portion (120).

Abstract: A key top member for a push button switch structure capable of facilitating change and modification of a design while eliminating deformation and misregistration of a display section, being accommodated to a variety of data, being increased in design properties and visibility, and being reduced in manufacturing cost. An upper resin sheet made of thermoplastic resin and having display sections such as a letter, a symbol, a pattern or the like printed thereon is formed with projections having configurations conforming to outer configurations of key top elements. The projections are each securely provided therein with a filler member made of photo-setting resin directly or through an adhesive.

Abstract: A system and method for reinforcing at least a portion of a structural member, including at least one chamber or compartment having an interior portion which substantially conforms to the dimensions and geometry of the structural member being reinforced; and a reinforcement material for filling the interior portion of one or more of the compartments or chambers. The reinforcement material filling one or more of the compartments or chambers of the present invention can be a pumpable polymeric material, an heat activated expandable material, or a self-curing material. The compartment or chamber can be a polymeric material, such as nylon, which can be solid, blow-molded, flexible, or expandable depending upon the selected structural member to be reinforced.

Abstract: A process of simultaneously molding either a plurality of shingles or double walled shingles or other substantially planar exterior building products is provided, such that a blow moldable thermoplastic material is provided, of a composite parison that is then blow molded in a hollow mold, to produce novel shingles according to the process. Ventilation and/or insulation can be provided to a hollow interior between spaced apart walls of a double walled shingle.

Abstract: A process of simultaneously molding either a plurality of composite shingles or double walled shingles or other substantially planar exterior building products is provided, each being comprised of two or more layers of thermoplastic shingle material, such that a weatherable capstock material is provided outside a core material, in the form of a composite parison that is then blow molded in a hollow mold, to produce novel shingles according to the process. Ventilation and/or insulation can be provided to a hollow interior between spaced apart walls of a double walled shingle.

Abstract: A method for fabricating a seal-integrated separator for a fuel cell is presented, with which seals can be accurately positioned and the assembling time for the fuel cells may be greatly reduced. The method comprises the steps of: providing an upper mold having a groove positioned corresponding to second and fourth seals disposed on one side of a separator body, and a lower mold having a groove positioned corresponding to first and third seals disposed on the other side of the separator body; holding the separator body between the upper mold and the lower mold; and injecting melted seal material to form the seals into each of the grooves in the upper mold and the lower mold through separate gates respectively formed in the upper and lower molds. Through this method, a seal-integrated separator having the first to fourth seals which are integrated on both sides of the separator body is fabricated.

Abstract: A method for using a single injection molding apparatus to manufacture at least two and up to four different levels of automobile trim pieces as well as automobile trim level pieces manufactured by the methods of this invention.

Abstract: A method of molding a high density composite article which, when completed, has opposed outer skins of fiber-reinforced plastics material and polymer mortar core between the skins. The method is performed by (a) providing an openable mold defining a mold cavity and an injection port through which polymer mortar may be introduced into the cavity; (b) opening the mold and placing within the cavity respective layers of fiber reinforcement to form the opposed outer skins; (c) closing the mold and injecting polymer mortar consisting of a resinous material loaded with high density particulate aggregate through the injection port into the cavity, between the layers of fiber reinforcement placed therein; and (d) applying sufficient pressure to the injected polymer mortar to ensure resin is separated from the polymer mortar and penetrates the said layers.

Abstract: A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: A method of manufacturing a composite structure uses a layer of an insulating material (22) as a mold for forming a substrate of a ceramic matrix composite (CMC) material (24). The insulating material may be formed in the shape of a cylinder (10) with the CMC material wound on an outer surface (14) of the cylinder to form a gas turbine combustor liner (20). Alternatively, the insulating material may be formed in the shape of an airfoil section (32) with the CMC material formed on an inside surface (36) of the insulating material. The airfoil section may be formed of a plurality of halves (42, 44) to facilitate the lay-up of the CMC material onto an easily accessible surface, with the halves then joined together to form the complete composite airfoil. In another embodiment, a box structure (102) defining a hot gas flow passage (98) is manufactured by forming insulating material in the shape of opposed airfoil halves (104) joined at respective opposed ends by platform members (109).

Abstract: A valve for controlling the flow of a gas therethrough which requires no machining in order to attain an effective seal between the valve seating surface and a rotatable plug element. The valve seat surface remains as cast while the plug consists of an overmolded plastic. The overmolding defines an array of pliable sealing ridges. The use of overmolding facilitates the use of cost-saving plastic materials, and obviates the need for expensive machining of the cooperating surfaces.

Abstract: In coloration of a shaped article composed of a curable resin, the addition operation can be reliably conducted and a reliable coloration effect can be obtained in both the single-color addition and in the multicolor addition. A liquid-phase, non-colored photo-curable resin is cured by irradiation with laser light and a lowermost layer 5n is formed. A liquid-phase, photo-curable resin is applied on the upper surface thereof and a colored layer 5n-1 comprising a cured non-colored region and a liquid-phase pool region is formed. A color ink is drop-wise added to the liquid-phase pool region. The pool region is irradiated with laser light and cured to the same hardness as that of the non-colored region. A block-like coating film having the prescribed thickness if formed from the surface coating film produced by the color ink covering the pool region. As a result, the formation of the next layer (colored layer 5n-2) on the upper surface of colored layer 5n-1 can be conducted without obstacles.

Abstract: The present invention is directed to a method of preparing an article of manufacture. The method includes bringing at least a portion of a heated thermoplastic sheet into contact with at least a portion of the first surface of a support having a plurality of perforations. A vacuum is formed on the second surface of the support, and portions the heated thermoplastic sheet are drawn through the perforations of the support and to the second surface side of the support. Thermoplastic attachment heads are formed on the second surface side of the support, from the thermoplastic material of the sheet that is drawn through the perforations. The thermoplastic sheet and the support are fixedly attached one to the other by means of the edges of the perforations being embedded in the thermoplastic material of the sheet drawn therethrough, and the thermoplastic attachment heads. Also disclosed are articles of manufacture, such as interior and exterior automotive body panels and components.

Abstract: A shaped composite article is prepared by a process wherein an aesthetic laminate having a clear outer arylate layer and a colored compatible resin layer is thermoformed into a desired shape, and then compression molded together with a reinforced resin material containing compatible resin to form a color composite of the desired shape having an outer layer of clear arylate polyester polymer with the compatible resin layer forming an adherent bond with the compatible resin in the resin reinforced material.

Abstract: A method of manufacturing an overmolded trim component includes providing a first mold portion and a movable mold element. The movable mold element includes first and second mold surfaces positioned at a first angle with respect to one another. The movable mold element is then positioned into the first position to define a first cavity. A first material is then introduced into the first cavity, thereby forming a substrate. The substrate includes a first substrate surface is at a second angle with respect to a second substrate surface. The movable mold element is then positioned into the second position to define a second cavity. A second material is then introduced into the second cavity, thereby forming an overmolded trim component. The movable mold element is oriented at a third angle with respect to the first substrate surface and at a fourth angle with respect to the second substrate surface.

Abstract: A far infrared tubular porous ceramic heating element which is suitable for various kinds of catalyst, heater and electric conductor . . . etc. Inside the body, a plurality of via holes is formed, and the crossing portions of the walls of via holes are formed in arc shape so as to prevent breaking and disturbance to heat flow.

Abstract: A plastic container contains a liquid, such as toilet water or soy sauce, and is suitable for containing a refill. The plastic container (1) has a tube (2) formed by rolling a plastic laminate in a tubular shape, a bottom wall (3) formed so as to be joined to the inner circumference of a lower end part of the tube (2) by an insert injection molding process, a hoop (4) formed on the outer circumference of an upper end part of the tube (2) by an insert injection molding process and a top cover (6) provided with a spout (5) and bonded to the upper end surface of the hoop (4).

Abstract: An outsole for a shoe, especially a house slipper, has an outer layer constituted of a fabric material, and a backing layer constituted of a shape-retaining, moldable material. The fabric layer and the backing layer are molded integrally together to provide the outsole with increased slip resistance, quieter usage and increased shape retention.

Abstract: The present invention is directed to a method of preparing an article of manufacture. The method includes bringing at least a portion of a heated thermoplastic sheet into contact with at least a portion of the first surface of a support having a plurality of perforations. A vacuum is formed on the second surface of the support, and portions the heated thermoplastic sheet are drawn through the perforations of the support and to the second surface side of the support. Thermoplastic attachment heads are formed on the second surface side of the support, from the thermoplastic material of the sheet that is drawn through the perforations. The thermoplastic sheet and the support are fixedly attached one to the other by means of the edges of the perforations being embedded in the thermoplastic material of the sheet drawn therethrough, and the thermoplastic attachment heads. Also disclosed are articles of manufacture, such as interior and exterior automotive body panels and components.

Abstract: Systems and methods for manufacturing composite webs including a substrate with one or more discrete polymeric regions located thereon are disclosed. The discrete polymeric regions are deposited by transferring molten thermoplastic composition from depressions on a transfer roll to a substrate. Each of the discrete polymeric regions is further formed to include multiple structures formed thereon. Those structures may include, for example, stems (capped or otherwise), hooks (as part of a hook and loop fastening system), pyramids, etc.

Abstract: There are disclosed a multi-color injection molding process for producing an ink-jet printer member comprising a plastics substrate and an elastic material layer that are integrally composited, which comprises melt-injecting into a mold in turn, a material for a plastics substrate and an elastic material composed of a thermoplastic elastomer; and an insert molding process for producing the ink-jet printer member mentioned above, which comprises placing in advance, a plastics substrate of a prescribed form in a mold, and melt-injecting an elastic material composed of a thermoplastic elastomer into said plastics substrate. The above processes are well suited for the production of the ink-jet printer member such as an ink tank valve for supplying a recording head with an ink to be filled in an ink chamber, also of a sealing member which is installed at an ink supply port or on the main body of an ink-jet printer and prevents an ink from leaking through the ink supply port or through the recording head.

Abstract: The invention relates to the production of a hybrid component, whereby a piece of metal sheet (1) is a least partly coated with plastic by injection molding, by means of the following steps: a) placing the metal sheet (1) in one mold half of an injection mold, b) closing the injection mold, such that a first mold cavity opposite an upper side (O) of the metal sheet (1) and a second mold cavity opposite an under side (U) of the metal sheet (1) are cut off from each other, c) treatment of the upper side (O) with plastic by means of at least a first sprue (9) to produce an essentially flat coating (4) connected to the metal sheet (1) and, finally, d) treatment of the under side (U) by means of at least one second sprue (10) to produce a reinforcing structure (6) connected to the metal sheet (1).

Abstract: The invention relates to a method for producing objects and object parts formed by an assembly comprising at least two plastic parts (10 and 5; 10? and 5?), which can move in relation to one another with at least one degree of freedom and which are provided with surfaces having at least partially complementary shapes such that, in at least one geometric configuration, they are solidly interconnected on a common surface (11; 11?) in close, clearance-free contact The inventive method comprises the following steps: 1) molding of a first part (10, 10?) by compression or injection; 2) removal of the second tool, the first part (10, 10?) remaining solidly connected to the first tool which serves as a piece of support equipment or is installed on a piece of support equipment (60); 3) compression molding of the second part using the whole (110) of the first part which is integral to the support equipment and a third tool; 4) removal of the first support tool (60) and the third tool (55) and extraction of the assembly

Abstract: A first parting film is held on a first flat laminating table in close contact with the first flat laminating table, and then wide prepregs are laid for plane lamination on the first parting film to form a large prepreg-laminate having a large area. A second parting film is held on a second flat laminating table in close contact with the second flat laminating table by suction, and then narrow prepregs to form a gridlike prepreg-laminate. The large prepreg-laminate is floated up by jetting air from the first flat laminating table is cut on a cutting table to obtain a prepreg-laminate skin. The gridlike prepreg-laminate is processed similarly to obtain a prepreg-laminate doubler. The prepreg-laminate skin and the prepreg-laminate doubler are carried from the cutting table to a laminating mold having a single-contour laminating surface so as to be superposed and are laminated to form a composite panel.

Abstract: A mold tool includes upper and lower sections defining a cavity within which a plastic film preform is placed before injection of plastic forming a molded article. The plastic film extends between an interface defined between the sections of the mold. The interface secures a position of the plastic film within the mold tool preventing movement during injection of plastic. The interface is specifically configured to secure the plastic film without damage. The specific configuration of the interface is determined according to a relationship between molding process parameters and physical characteristics of the plastic film.

Abstract: A method for fabricating a seal-integrated separator for a fuel cell is presented, with which seals can be accurately positioned and the assembling time for the fuel cell units may be greatly reduced.

Abstract: The present invention involves a process that includes injecting a potting compound such as an epoxy through a hollow portion (2B) of the central mandrel (2) and onto the inner layer(s) of a multi-layered fiber bundle (3) and through the outside of the bundle and onto the outer layer(s) of the bundle. By potting through the central mandrel (2), the potting compound distributes evenly throughout the inner fibers of the bundle (3). The steps may be sequentially or simultaneously. Preferably it is done as a two-step process, with the first step being to apply the potting compound through the central mandrel (2) and onto the inner fibers first. The second step is to pot around the outer layer of the fiber bundle (3) to finish the process. The resultant product is also disclosed.

Abstract: The method of making a tubular member having a continuous and uninterrupted cured elastomeric resin coating on an outer surface of the member includes forming a continuous uninterrupted tubular layer of uncured elastomeric resin and drawing the resin layer against the surface of the tubular member to be coated by applying suction between the resin layer and the surface of the tubular member so that the resin adheres to the surface of the tubular member. The elastomeric resin may then be cured to produce the final product. Apparatus for carrying out the process includes, in sequence, a coating zone including a sub-atmospheric chamber, a heating zone and a feed mechanism for advancing the tubular member relative to the coating and heating zones. A method includes molding a distal end cap on an open end of a length of a preformed tubular sleeve member that may be used for prosthetic applications.

Abstract: A method for repairing fiber-reinforced composite structures while maintaining original EM and lightning protection using carbon nanotubes, fibers, and thermoset resins is disclosed. According to one embodiment of the invention, the method comprises preparing a damaged area for repair; preparing a repair patch for the damaged area, the repair patch comprising nanotubes; applying the repair patch to the damaged area; and curing the repair patch. A repair patch for a composite structure having a conductive layer is disclosed. According to one embodiment of the present invention, the repair patch includes a binder and nanotubes. A repair resin for repairing a composite structure having a conductive layer is disclosed. According to one embodiment of the present invention, the repair layer includes a resin and nanotubes. A putty for repairing a composite structure having a conductive layer is disclosed.

Abstract: Optical windows for intracorporeal devices, intracorporeal devices comprising a window and a method for forming a window for an intracorporeal device are provided. The method comprises placing within a mold an assembly comprising a mandrel located within a pair of parts separated by a collar of window material, heating the window preform effective to cause the window material to soften, and applying force to urge together the pair of parts to deform the window material so as to form a window. The intracorporeal devices, such as imaging devices, include guidewires, catheters, endoscopes. In addition, the method is suitable for joining plastic parts to other parts, such as metal and ceramic parts.

Abstract: A unitary two component article for personal hygiene, as a toothbrush, wherein the same is formed by injection molding of two differing plastic materials, which plastics do not adhesively or chemically bond to each other, thereby facilitating the manufacturing process. The two differing plastic parts of the toothbrush are mechanically connected, as by interfitting portions of the two plastic components and as by shrinking one plastic component about the other.

Abstract: A method is described for producing a pipe end socket (3) made of thermoplastic material with a sealing ring (5) which engages in a form-fitting manner on the inside of the socket in a circumferential bead (4) and which comprises a sealing part (6) and a supporting part (7), with the sealing ring (5) being introduced into a preformed bead region and is then tightly held in a form-fitting manner in the circumferential bead (4) by a final forming of the preformed bead region. In order to provide advantageous process conditions it is proposed that the pipe end socket (3) with the circumferential bead (4) is preformed at a deformation temperature corresponding at least to the softening temperature with an overdimension which allows an insertion of the sealing ring (5), and after the cooling below the softening temperature and after inserting the sealing ring (5) said pipe end socket with the circumferential bead is pressed into the final shape by taking into account a cooling-induced shrinkage.

Abstract: A method for fabricating a protective helmet includes the steps of: (a) providing a fiber-based filler, such as a fiberglass sheeting; (b) mixing course ceramic particles into a thermoset resin; (c) impregnating the resin/ceramic particle mixture into the fiber-based filler; (d) forming or molding the impregnated fiber-based filler into a shape of a protective helmet; and (e) curing the resin mixture impregnated into the fiber-based filler. The course ceramic particles are preferably created by chopping a ceramic material. The presence of the ceramic particles in the composite helmet substantially reduces the heat reflectance of the helmet; while also reducing the overall weight of the helmet, since the ceramic material weighs less than the portion of resin material that the ceramic material is being used in place of. Finally, because the ceramic particles are course, they will not all flow to “low spots” in the helmet during the curing process.

Abstract: A variety of hollow structures with unique morphologies were manufactured with a rotational spinning technique. Phase separation of soluble solutions or emulsions was induced within a filled mold as it was being rotated about one of its axis. The density difference between phases results in sediment at the inner lumen of the mold under centrifugal forces. After or during sedimentation, gelation of the phase-separated particles fixes the hollow structure morphology and the solvent remains in the center of the mold. The solvent is removed from the mold resulting in a coating or tube. By controlling the rotational speed and the formulation chemistry, the tube dimensions and wall morphology can be manipulated. This technique offers a new approach to the manufacture of polymeric tubes. It requires small quantities of starting material, permits multi-layering of tubes, is applicable to diverse polymers and can result in highly diffusive hollow structures while maintaining good mechanical strength.

Abstract: An article including a panel structure mountable in an automobile vehicle to form a part of the vehicle interior thereof, and a process for making the same are disclosed. According to this process, an outer layer defining at least a portion of the exposed exterior surface of the structure is prepared by applying a water-dispersed composition containing a thermoplastic polyurethane and a heat-activated crosslinking agent onto a mold surface and thereafter drying the composition. Next, a composition comprising (i) a poly(vinyl chloride) resin and at least one plasticizer and/or (ii) a thermoplastic polyurethane resin material is gelled onto an inner surface of the outer layer while on the outer layer is retained on the mold surface. The gelled composition is then fused to form an inner layer interfacially chemically bonded to the outer layer. The layered composite structure is united with the reinforcing substrate so that the reinforcing substrate serves to reinforce the outer layer.

Abstract: An electrically driven membrane process apparatus is provided comprising a first spacer having a perimeter having a surface with an inner peripheral edge defining an opening, and a recess formed on the inner peripheral edge, and an ion exchange membrane having an outer edge fitted within the recess. The spacer can further comprise a plurality of bosses and an ion exchange membrane having a corresponding plurality of apertures for receiving the bosses. The spacer can include a plastic mesh consisting essentially of polypropylene or polyethylene, and a perimeter surrounding the plastic mesh, the perimeter comprising material selected from the group consisting of thermoplastic vulcanizates and thermoplastic elastomeric olefins. The spacer can have an upstanding seal member depending therefrom, received by groove within a corresponding frame member. A second spacer is also provided having a continuous flange depending from its surface and surrounding a throughbore, for pinching a portion of the first spacer.

Abstract: An assembly is disclosed that includes an etched hole-fill standoff; a tooling plate contacting the etched hole-fill stand-off, the stand-off and tooling plate being aligned to each other; a device having holes to be filled removably contacting the stand-off, the stand-off and device being aligned to each other; the device and the stand-off each having at least one hole, the hole of the device being aligned with the hole of the stand-off. An assembly is also disclosed comprising an etched hole-fill standoff, the stand-off comprising an etched layer bonded to a non-etched layer. A method of filling holes in a substrate having a plurality of holes to be filled includes the steps of providing an etched hole-fill stand-off, aligning the stand-off to a tooling plate, aligning the substrate to the stand off and placing the substrate in contact with the stand-off, and filling the plurality of holes of the substrate.

Abstract: An apparatus and method for providing gross location, planarization, and mechanical restraint to one or more electronic components such as semiconductor dice to be subjected to stereolithographic processing. A double platen assembly including a first platen and a second platen mutually removably connected and configured and arranged to substantially secure an electronic component assembly in position therebetween. At least one of the platens is configured such that a portion of electronic components of a carrier substrate secured by the double platen assembly is viewable for exposure to an energy beam such as a laser beam used to cure a liquid into an associated dielectric stereolithographic packaging structure. Another embodiment includes the use of an adhesive-coated film for holding, locating and securing a plurality of individual electronic components for processing. A method of forming solder balls is also disclosed.

Abstract: This method permits manufacturing EPDM rocket motor insulation in which carbon fibers are dispersed and immobilized in the EPDM polymeric matrix but are not excessively fractured or fragmentized, i.e., broken into smaller fragments, when encountering degrees of shear necessary to homogeneously or otherwise distribute or disperse the carbon fibers in the EPDM polymeric matrix. The method is substantially solvent free and is performed via distributive/reduced shear mixing to distribute the fragile carbon fibers into a rubber matrix without excessive damage. According to one embodiment, at least about 50% of the elastomer composition introduced into the mixing apparatus is liquid EPDM terpolymer having sufficiently low molecular weight and high diene content to permit dispersion of the carbon fibers in the EPDM without substantial fragmentation of the fibers.

Abstract: A device for finishing the ends of concrete posts, piers or columns has a form for imparting a smooth transitional shape to the periphery of the concrete post, piers or columns. The form may be shaped and sized to fit into a conventional prefabricated tubular form for concrete posts, piers, columns and the like. The device may also have a central finishing plate for producing a smooth end surface to the concrete posts, piers or columns. The central finishing plate may be connected to a driver, such as a drill motor and the like, to impart a smooth finish to the end surface of concrete posts, piers or columns. The central finishing plate may also be used to center an anchor bolt.

Abstract: A mold is described for molding an elastomeric glazing profile in situ on a single major face of a sheet of glazing material, e.g. a glass sheet. The mold comprises a first mold segment and at least one further mold segment which are relatively movable into intimate contact, so that they define, together with the sheet, a mold cavity for molding the profile on the single major face. The profile has a show face, (i.e. one which is visible in use), and the portion of the mold cavity that molds the show face is entirely formed by a single mold segment to avoid mold lines on the show face. Also described are a corresponding molding method and the glazing product thereby obtained, which may be used as a vehicle window.

Abstract: In a method of reinforcing an existing concrete electric pole having an annular side wall, an inner hollow portion provided therein and an opening portion formed to a position of the annular side wall to be penetrated therethrough, at least one of a predetermined amount of mortar, a predetermined amount of sand and a predetermined amount of gravel is injected into the inner hollow portion of the electric pole through the opening portion. A reinforcing member for reinforcing the electric pole is injected into the inner hollow portion of the electric pole through the opening portion.

Abstract: A multi-material runner gate system allows effective de-gating of elastomeric materials that would otherwise stretch and/or flex reducing de-gating forces at the gate upon separation of the molds.

Abstract: A stay-in-place method of manufacturing a composite form that is used to provide a strong and durable concrete structure. The form includes a composite shell having an inner wall surface defining an enclosure into which concrete may be poured and allowed to harden. The composite shell may be made of one or several layers of fabric having a resin matrix impregnated therein. The concrete hardens to form a concrete core within the enclosure and a liner is affixed to the inner wall surface of the composite shell to protect the composite shell from alkalinity in the concrete core. The liner includes at least one sheet of a water-impermeable material to protect the concrete core from water and other corrosive elements. The fabric layers are selected such that the fibers elongate as the concrete is poured into the enclosure due to a weight of the concrete and partially shrink back to compensate for shrinkage of the concrete as the concrete dries to form the concrete core.

Abstract: A method of making a catheter balloon or other expandable tubular medical device or component thereof formed of a compacted porous polymeric material, in which a tube of porous polymeric material is axially compacted, preferably without increasing the outer diameter of the tube, by positioning heat shrink material on the porous polymeric tube and heating the heat shrink material to decrease the length and diameter of the heat shrink material.

Abstract: Cable tie and method of making the same. In a preferred embodiment, the method comprises continuously forming a length of strap material using a rotary extrusion process, the strap material having laterally-extending teeth disposed along its entire length. The continuous length of strap material is then cut into individual straps of desired length, with the ends of each strap being shaped to desired profiles. A transverse hole may also be formed in the strap proximate to its front end. A front portion comprising a head is then insert-molded around the front end of the strap and, if present, the transverse hole in the strap. The head is provided with a transverse channel through which the tail end of the strap may be inserted and a locking tang lockably engageable with the teeth once inserted therepast.

Abstract: A first parting film is held on a first flat laminating table in close contact with the first flat laminating table, and then wide prepregs are laid for plane lamination on the first parting film to form a large prepreg-laminate having a large area. A second parting film is held on a second flat laminating table in close contact with the second flat laminating table by suction, and then narrow prepregs to form a gridlike prepreg-laminate. The large prepreg-laminate is floated up by jetting air from the first flat laminating table is cut on a cutting table to obtain a prepreg-laminate skin. The gridlike prepreg-laminate is processed similarly to obtain a prepreg-laminate doubler. The prepreg-laminate skin and the prepreg-laminate doubler are carried from the cutting table to a laminating mold having a single-contour laminating surface so as to be superposed and are laminated to form a composite panel.

Abstract: A cured resin and fiber part generally can be manufactured by providing a mold that defines a cavity having at least one shape-defining surface. An in-mold paint sheet having a bonding side and a finish side can be positioned in the cavity of the mold such that the finish side of the in-mold paint sheet is positioned adjacent to the shape-defining surface of the mold. A mixture of a thermoset resin and a plurality of reinforcing fibers are then introduced into the cavity of the mold such that the resin and fiber mixture contacts the bonding side of the in-mold paint sheet. The in-mold paint sheet and resin and fiber mixture are then compressed in the mold while being heated causing the resin and fiber mixture to be cured and bonded to the in-mold paint sheet resulting in a part having the finish side of the in-mold paint sheet as a finished surface of the part.

Abstract: A process for forming a cushion layer of a preselected thickness on an inside of a prosthetic liner body is provided and includes the steps of introducing the liner body into a mold cavity; disposing a sufficient amount of cushioning material into the inside of the liner and directing a mandrel into the inside of the liner body. The driving action of the mandrel causes the cushioning material to be dispersed between the mandrel and the liner body, thereby forming the cushioning layer of preselected thickness.