Abstract: A manufacturing method for a composite coil spring includes the following steps: preparing a mold, winding a coil former around a mandrel of the mold, winding composite material pre-preg, compressing and heating, opening the mold and detaching the mandrel and the coiled coil former.

Abstract: The object of this invention is the method of manufacture of a symmetric element of a round ring and cone-shaped ring applicable in serial production. The application area of the invention is particularly the prefabrication of ceramic coating elements, which match together and which are assembled in straight walls, a surface coating containing cylinder rings and cone-shaped rings. Good application objects are for example the cyclones and the ducts of circulating bed boilers, carburetor plants, etc. various combustion chambers and high temperature devices. The concerned elements have special conditions concerning their tightness, so that their seam surfaces must be shaped so that they are profile surfaces differing from plane surfaces, profile surfaces having the capacity to resist to leakage through seam better than straight surfaces.

Abstract: This invention refers to a method and a device for use in connection with the fabrication of multilayer products (8) such as composites and bonded multilayer sheet products, ect. by means of the so-called “bagging technique,” to increase the compressive pressure (P) on the product being created beyond normal atmospheric pressure. In the bagging technique, which is used to join a plurality of different material layers with one another to form a unit via polymeric binder layers, atmospheric pressure is normally used to press the various objects together in that they are enclosed in a depressurized gas-impervious bag (9, 21) while the various layers are joined to form a unified product.

Abstract: Methods for making a tubular device that has a rim disposed at one end thereof. In one method, a sleeve having an expandable profiling surface is inserted into an end of the tubular member, and the profiling surface is expanded to form a shoulder projecting outwardly from the tubular member adjacent the end of the tubular member. The profiling surface is collapsed inwardly away from tubular member, and a return margin is formed directed inwardly from the shoulder, distal the tubular member. In another method, return margin of the tubular device adjacent an end is folded inwardly and superposed on an inner surface of the tubular device adjacent the folded margin. A sleeve having an expandable profiling surface is inserted into the end of the tubular device, and the profiling surface is expanded to form the rim comprising a shoulder projecting outwardly from the tubular member and the return margin. As a result, the fold between the shoulder and the return margin defines an edge of the tubular member.

Abstract: The present invention relates to methods and apparatus of molding composite parts by liquid resin infusion. The invention involves the creation of temporary resin distribution channels on the surface of a preform to aid in the distribution of resin during infusion. In general, these methods are improvements over the art because the molds are cheaper to make, the parts produced are of higher quality, minimal waste is produced and the time to infiltrate the preform is reduced. Hollow tubes with moveable portions provide Channels which Assist in Resin Transfer Molding of composites (CARTM).

Abstract: A method is provided for fabricating a concrete slab in a substantially horizontal slip casting process method, concrete mix is fed into a mold through a delimited cross section moving progressively in the casting process so as to form a concrete product of a desired shape. Onto the surface of the casting bed (1) is placed a core (3, 9, 10, 11) capable of delimiting the cross section of the concrete product (5, 5?) so as to provide an opening or a provision for an opening in the bottom surface of the slab. A core is provided for obtaining an opening or a provision for an opening. The structure and/or material of the core is/are such that the core is capable of yielding in vertical direction. A core may also be a multipart core, the outer part of which becomes detached from the inner part of the core in conjunction with lifting off the concrete slab from the casting bed.

Abstract: A fiber composite structural component such as a fitting, bracket, mounting or the like is produced by applying fiber material such as fiber threads or fiber yarns in an automatic circular weaving operation to a core that has at least two sections, to form a fiber material body (6). One core section is removed from the fiber material body when the weaving is completed. The body is then deformed in a mold that has the contour of the finished structural component with at least one mold core section still in the fiber material body. The deformed configuration of the structural component is then impregnated in an RTM device with a resin and hardener followed by curing. Reinforcements may be inserted or secured to the fiber material body prior to the impregnated and curing step.

Abstract: The present invention relates to a molding material for the precision casting and dead-mold casting of metals or metal alloys comprising plastic and/or carbon aerogels, and a process for the preparation of such molding materials. The molding material comprises highly porous open-cell plastic and/or carbon aerogels, obtainable by the sol-gel polymerization of organic plastic materials, optionally followed by partial or complete pyrolysis of the plastic aerogel obtained.

Abstract: A manufacturing method for a golf club head comprises steps of: forming a plurality of through holes and annular recessed flanges thereof on a crown plate, a sole plate and a side plate of a main body blank; preparing a plurality of carbon-fiber plates by carbon-fiber fabrics; inserting a plurality of carbon-fiber reinforcing members and an air-inflating bag into the main body blank; adhering the carbon-fiber plates to the corresponding annular recessed flanges; inserting the main body blank into a die assembly and then injecting air into the air-inflating bag to thereby support the carbon-fiber plates and the reinforcing members; drawing out the flat air-inflating bag and precise processing the finished main body to accomplish an end product.

Abstract: An apparatus and method for holding a mold assembly and molding an optical lens using the same. In one aspect, the present invention provides an apparatus for holding a mold assembly, wherein the mold assembly includes a front mold, a back mold and a strip wrapping around the edges of the front mold and back mold to form a sleeve. In one embodiment, the apparatus includes a first portion and a second portion. The first portion has a top part, a bottom part, and a middle part connecting the top part and the bottom part, the middle part including a base and a holder coupled to the base. The second portion has a top part, a bottom part, and a middle part connecting the top part and the bottom part, the middle part including a base and a holder coupled to the base.

Abstract: Long carbonaceous moldings and long carbonaceous products as well as methods of production thereof by which carbonaceous products can be obtained without allowing twisting or curving and with less frequent occurrence of cracking etc. even when subjecting the heat treatment and which are excellent in mass productivity are provided. The long carbonaceous moldings have an aspect ratio of 3 to 20 and showing fluctuations in the density thereof of not more than 0.05 Mg/m3 throughout the whole moldings.

Abstract: The present provides deformable molds and methods for manufacturing ophthalmic lenses using deformable molds. The molds of the invention may be used in the custom manufacture of ophthalmic lenses.

Abstract: The present invention relates to elastomeric contact masks, and methods of making these contact masks by complementary molding using complementary molds. The contact masks are made of polymer gels, including hydrogel materials. The complementary molds of the present invention include at least one elastomeric half mold. Also disclosed are methods of continuous complementary molding.

Abstract: A method of fabricating a microstructure is provided. The method includes the step of providing a layer of a polyermizable material. A solid is brought into contact with the layer of polymerizable material so as to alter the shape of the upper surface of the layer. Thereafter, the layer of polymerizable material is polymerized such that the layer solidifies and the upper surface thereof assumes a desired three-dimensional configuration.

Abstract: In a method for forming a micro-pattern on a substrate (200), polymer material having a solvent is coated on the substrate, thereby forming a polymer film on the substrate. Then, a mold (204) having a predetermined shape is compressed into the polymer film (202) on the substrate by employing a predetermined compression technique to entail a plastic deformation of the polymer film, thereby patterning the polymer film. This compression procedure is performed at a room temperature, e.g., of about 10 to about 30° C. In the present invention, before the mold (204) is pressed into the polymer film (202), a free volume in the polymer film is previously increased so that a pressure applied on the polymer material needed to plastically deform the polymer film is reduced. Thereafter, etching is performed on the substrate through the use of the patterned polymer film as an etching mask, thereby forming a micro-pattern on the substrate.

Abstract: A flexible or semi-rigid support fixture is sized and shaped to supportably engage a surface of a polymeric matrix object such as an organic bonded abrasive grinding wheel. The support fixture is utilized to support the object to help prevent slumping and/or expansion during thermal curing operations. The fixture is fabricated from a material, such as silicone rubber, that is capable of withstanding heat commonly associated with thermal curing operations and which provides sufficient resilience to permit use with objects manufactured within a relatively wide range of dimensional tolerances. Suitable materials include silicone rubber or other polymers or copolymers such as PTFE, FEP, Polyimide or blends with or without fillers or substrates.

Abstract: A connector element for connecting frame parts at a joint location in a bicycle frame is made of a single part of structural fiber based material, typically carbon fiber material, after reticulation in a mold exploiting the expansion of a core on which windings of fiber fabric material are provided, to obtain the application of a uniform radial pressure on the layers of fiber based material. In one embodiment, the connector element defines a bicycle bottom bracket and tubular extensions extending therefrom for connection to elements of the bicycle frame.

Abstract: A connector element for connecting frame parts at a joint location in a bicycle frame is made of a single part of structural fiber based material, typically carbon fiber material, after reticulation in a mold exploiting the expansion of a core on which windings of fiber fabric material are provided, to obtain the application of a uniform radial pressure on the layers of fiber based material. In one embodiment, the connector element defines a bicycle bottom bracket and tubular extensions extending therefrom for connection to elements of the bicycle frame.

Abstract: A connector element for connecting frame parts at a joint location in a bicycle frame is made of a single part of structural fiber based material, typically carbon fiber material, after reticulation in a mould exploiting the expansion of a core on which windings of fiber fabric material are provided, to obtain the application of a uniform radial pressure on the layers of fiber based material. In one embodiment, the connector element defines a bicycle bottom bracket and tubular extensions departing therefrom for connection to elements of the bicycle frame.

Abstract: The invention relates to a method for producing models or pre-forms, comprising the following method steps: (a) producing a shaped core from a water-soluble block material, (b) coating the shaped core with a curable polymer, (c) curing the curable polymer at from 25 to 250° C., and (d) removing the core material by treating the coated core with water.

Abstract: An exemplary method of manufacturing a polymer matrix composite electromagnetic shielding structure includes pretreating a dry fiber reinforcement with a composition including a carrier and a conductive element, laying out the pretreated reinforcement to form a pre-form structure, applying a resin to the pre-form structure, and curing the resin at room temperature. Another exemplary method of manufacturing a polymer matrix composite electromagnetic shielding structure includes laying out a plurality of dry fiber reinforcements, placing at least one ply between any two of the plurality of dry fiber reinforcements, the ply having a non-woven including a conductive material, applying a resin to the plurality of dry fiber reinforcements and the at least one ply, and curing the resin.

Abstract: A method for forming a hollow FRP article by internal pressure molding includes positioning a FRP prepreg on a periphery of an airtight internal-pressure holding tube, inserting a composite body including the internal-pressure holding tube and the prepreg into a vacuum chamber containing a forming die, evacuating the vacuum chamber in an isolation state where the composite body and the forming die do not contact each other, and clamping the forming die to bring the forming die and the composite body into contact with each other and heating the forming die with an application of pressure to an inside of the internal-pressure holding tube after completion of the evacuating step.

Abstract: The invention relates to a method of manufacturing a ski (1) comprising at least one binding-raising zone (5) formed by an extra thickness of the structure of the ski forming a projection in the region of the zone of the runner (2). Such a ski has a groove (12) let in over at least a portion of the length of each of its lateral faces, said groove (12) being located between the upper face (6) of the raising zone (5) and the edge (9) of the ski.

Abstract: A method of manufacturing a one piece, composite, hockey stick in an autoclave. A mandrel is provided which has a non uniform cross section. Pre-preg flags are wrapped around the mandrel. Provision is made so that when the wrapped mandrel is inserted in a pressure application tube, a portion of the wrapped mandrel is separated from the pressure application tube by one or more spacers. Pressure is then applied to the pressure application tube which in turn applies the pressure to the spacers. The spacers then apply the pressure to the wrapped mandrel to compact the pre-preg on the wrapped mandrel. Next the spacers are removed and the pre-preg is cured. Finally, a blade is formed around the pre-preg flag.

Abstract: Precisely configured, especially of geometric shape, flakes of liquid crystal material are made using a mechanically flexible polymer mold with wells having shapes which are precisely configured by making the mold with a photolithographically manufactured or laser printed master. The polymer liquid crystal is poured into the wells in the flexible mold. When the liquid crystal material has solidified, the flexible mold is bent and the flakes are released and collected for use in making an electrooptical cell utilizing the liquid crystal flakes as the active element therein.

Abstract: This invention refers to a method and a device for use in connection with the fabrication of multilayer products (8) such as composites and bonded multilayer sheet products, ect. by beans of the so-called “bagging technique,” to increase the compressive pressure (P) on the product being created beyond normal atmospheric pressure. In the bagging technique, which is used to join a plurality of different material layers with one another to form a unit via polymeric binder layers, atmospheric pressure is normally used to press the various objects together in that they are enclosed in a depressurized gas-impervious bag (9, 21) while the various layers are joined to form a unified product.

Abstract: An apparatus is provided for producing a substrate for PDP, which can easily reduce ununiformity of a dielectric layer and defects of ribs. The apparatus is so constituted that it comprises: a table for the plate, a rib precursor supplying portion for providing a precusor of the ribs on the plate, a pliable mold having at least groove portions provided in parallel with each other at a fixed distance, which is disposed on the precursor of the ribs provided on the plate, a mold pressing portion for applying a pressure to the mold, thereby to contact the mold closely with the plate via the precursor of the ribs, and a driving portion for moving the mold pressing portion along the groove portions of the mold.

Abstract: A method and apparatus is disclosed for transferring a decorative image to a bowling ball by sublimation from a transfer sheet. The method includes applying at least one transfer sheet containing sublimation inks representing a decoration, such as an image or graphic, to the outer surface of the bowling ball and transferring the decoration from the transfer sheet to the bowling ball by applying sufficient heat and pressure to sublimate the inks. A heat press apparatus is one exemplary apparatus that is contemplated for providing the heat and pressure. The heat and pressure may be maintained after sublimation to allow the inks to penetrate beneath the outer surface of the bowling ball. This allows decorating the bowling ball with a durable image or graphic that does not does not affect the performance of the bowling ball. The decoration may cover the entire bowling ball, or any portion thereof.

Abstract: A thermal pressure die for pressing and heating a trim cover assembly for automotive seat into a desired uneven configuration, the trim cover assembly having a decoratively finished outer surface with aesthetic solid or projecting decorative patterns defined thereon. A protection element of elastic and heat insulation property is provided on an uneven die surface of the die which is to be brought into pressing contact with such decoratively finished outer surface of trim cover assembly. Hence, the solid or projecting decorative patterns on the trim cover assembly outer surface are protected by the protection element against any deformation due to pressure and heating generated in the thermal pressure die.

Abstract: The present invention is a method for making a composite structure that includes three resin impregnated structural cloth layers including a bottom sheet, a top sheet and a core sheet. The core sheet is a continuously curved shape with flat valleys that are bonded to the bottom sheet and flat peaks that are bonded to the top sheet. In the invention process, a dry core sheet is sandwiched between two wax core molds that form the core sheet. The core molds and the core sheet are sandwiched between dry top and bottom sheets by rigid molds as the flat peaks and valleys of the core sheet make contact with the top and bottom sheets through openings in the core molds. Liquid resin is transferred into the dry sheets and then cured. The lay up is disassembled and the wax core molds are melted and drained from the finished, rigid structure.

Abstract: The present invention is a method for one piece molding of closed shapes which have interior surface features. The method involves the dissociation of the mold for the interior surface of the closed shape which is removed through an opening in the closed shape upon dissociation.

Abstract: An auxiliary jig used with a couple of jigs for forming a structure made of a fiber-reinforced composite by heating under a pressure. The auxiliary jig is provided between the jigs while heating the structure under a pressure to prevent the jigs from falling down and to restrain a resin contained in the fiber-reinforced composite from flowing out from an interspace between the jigs.

Abstract: A catheter which has resistance to collapsing when bent, and a method for producing such a catheter.

Abstract: A method for producing a composite component having a variable thickness includes placing a caul member over a plurality of laid-up prepreg plies supported by a mold. The mold includes a cavity for receiving the lay-up that is defined by a bottom surface, a plurality of walls extending upwardly from the bottom surface, and an open upper face surrounded by a mold edge. A support flange extends inwardly toward the center of the cavity from each of the walls at a predetermined distance from the bottom surface. The caul is made from an anisotropic material so that the caul is basically rigid about lateral axis and flexible about a longitudinal axis. During an autoclave curing process, the caul applies pressure along the length of the lay-up to draw the caul into engagement with the support flange, which serves as a stop to prevent further movement of the caul.

Abstract: There is presented a method of connecting a plurality of mandrels to one another to constitute an integral mandrel 10, forming a fabric 1 on the surface of the integral mandrel, and infiltrating the formed fabric with matrix. A plurality of products can simultaneously be manufactured, and this can remarkably reduce fiber loss and enhance productivity.

Abstract: Fine particles (23) are oriented and dispersed in a polymer medium to obtain a composite material (24), which is high-density compression molded to such a size that a photonic band gap develops, thereby obtaining a photonic crystal element (26). The orientation of the fine particles (23) in the polymer medium can be carried out on a scale (tens of micrometers to several millimeters) where required manipulations can be done with ease.

Abstract: Improvements are disclosed for an apparatus for continuously molding small fastener elements integral with a base web from a flowable resin. The apparatus comprises a cylindrical mold roll rotatable about an axis and defining small fastener element-shaped mold cavities in the surface thereof, and pressure-applying means to apply operating pressure to force the resin into the cavities at a pressure zone. The pressure-applying means and mold roll define a mold gap therebetween for forming the base web. The advantageous use of relatively long mold rolls, to produce a correspondingly wide web, and the use of higher molding pressures, e.g. to form very small fastener elements, is enabled by various improvements, including means to maintain the mold gap at a desired thickness profile across the length of the molding region of the mold roll under operating pressure. In some cases the pressure-applying means includes a pressure roll, in other cases it includes a resin nozzle assembly or pressure head.

Abstract: A process for fabricating a custom breast prosthesis or an intermediate casting form for a breast prosthesis, in which the task of creating the intermediate casting form is considerably simplified, and enables a shaping of the casting form, in situ.

Abstract: In a device for handling plastic material, such as a stamping device for stamping detergent bars, an elastomeric layer is provided on the handling surface which has good adhesion to the handling surface and good release from the plastic material. The elastomeric layer comprises at least two elastomeric coatings of different properties and/or compositions.

Abstract: The device is formed of a strand of flexible material that is helically coiled in the form of a preformed elongated member having adjacent coils removably bonded together. In using the device, the preformed member is embedded in concrete when in a wet state with one end of the preformed member extending at or close to the surface of the concrete. After the concrete has solidified, the end of the preformed member is pulled to break the bonds between adjacent coils to lengthen and reduce the diameter of the member to allow the strand to be removed from the concrete to form an aperture in the concrete from the surface.

Abstract: A method for making freeform-fabricated core composite articles using freeform-fabricated machine. The articles are capable of being utilized as end products rather than prototype models by creating a core having an interior structure to provide strength to the core and to enhance the strength to weight ratio of the article.

Abstract: Channeled articles having very small diameter channels spaced very closely can be made by packing elongated cores in a fixture, clamping them, and then introducing matrix material around the cores. The matrix material is formed into a unitary body and solidified. The cores are pulled out, leaving open channels where they had been. Some core and matrix combinations will permit the cores to be pulled out. Others require a core release coating to be applied to the cores. The cores can be metal or ceramic or polymer, and the matrix can be metal or ceramic or polymer. The cores can be solid, or hollow. Rather than pulling the cores out, if they are polymer, they can be burned out. The matrix can be formed by liquid state, solid state, or hybrid liquid/solid state techniques. A related technique uses hollow cores, which are not pulled out, but which remain in the body after unification. For such tube-walled articles, the matrix can be formed similarly. Rather than insuring core release, core retention is required.

Abstract: A method for molding and aligning microstructures on a patterned substrate using a microstructured mold. A slurry containing a mixture of a ceramic powder and a curable fugitive binder is placed between the microstructure of a stretchable mold and a patterned substrate. The mold can be stretched to align the microstructure of the mold with a predetermined portion of the patterned substrate. The slurry is hardened between the mold and the substrate. The mold is then removed to leave microstructures adhered to the substrate and aligned with the pattern of the substrate. The microstructures can be thermally heated to remove the binder and optimally fired to sinter the ceramic powder.

Abstract: A manufacturing method comprising the steps of forming at first solidified wax layer of a desired shape, depositing onto the first solidified wax layer at least one layer of a liquid resin formulation, solidifying the layer of liquid resin formulation, depositing a second wax layer on to the combination of the first solidified wax layer and the layer of solidified resin formulation, solidifying the second wax layer, and separating the solidified resin formulation from first and second wax layers. Preferably, the resin formulation comprises at least one monofunctional water soluble vinyl or acrylic monomer in combination with a low molecular weight aliphatic polymer having acrylic or methacrylic acid functionality. The solidified wax and resin formulation layers can be machined as may be desired to form mold of a given shape comprising wax layers when the layer of formulation is separated from the wax layers.

Abstract: A method for manufacturing a golf club head with a face component composed of a plurality of plies of pre-preg material and having a striking plate portion with a thickness in the range of 0.010 to 0.250 inches is disclosed herein. The golf club also has a crown component composed of a plurality of plies of pre-preg material and a sole component composed of a plurality of plies of pre-preg material. The golf club head is manufactured using a bladder compression molding process.

Abstract: A method of manufacturing hollow, fiber reinforced thermoplastic composite articles, such as a pressure vessel, is disclosed. The thermoplastic binder is chosen to bind the reinforcing fibers together, to provide strength, and to provide ease of manufacture. The method includes placing a preform with an inflatable core into a mold, pressurizing the inflatable core, and heating the mold to enable the thermoplastic binder to melt and distribute throughout the preform, binding the reinforcing fibers. The article is then cooled and removed from the mold, resulting in a hollow molded article. The inflatable core may be removed from the article and reused, or the core may become an integral part of the finished article.

Abstract: A method and apparatus for molding thermoformable sheet material is set forth. The method includes the steps of providing a conventional stamp type mold, one section of which provides a compliant mold member which is augmented by diaphragm. The diaphragm coacts with the compliant member during a molding phase to ensure dimensional uniformity in the molded article. Further, tight or detailed areas are easily molded by making use of the compliant and diaphragm members. In a further embodiment, tension adjusting is achieved during molding by a series of discrete tension members. The tension members cooperate with the compliant and diaphragm members to significantly improve dimensional uniformity and prevent wrinkling in the molded article.

Abstract: A method for transferring a three-dimensional structure onto a substrate, which includes filling a plurality of concaves arranged on a sheet-form mold with a paste-like structural material, temporarily fixing the mold to a support member, contact-bonding the structural material in a state in which the structural material has the adhesion property or bonding property to the substrate together with the mold, releasing the temporary fixation of the mold by the support member after the contact-bonding, and removing the mold from the substrate, thereby transferring a three-dimensional structure onto the substrate.

Abstract: The object of this invention is the method of manufacture of a symmetric element of a round ring and cone-shaped ring applicable in serial production. The application area of the invention is particularly the prefabrication of ceramic coating elements, which match together and which are assembled in straight walls, a surface coating containing cylinder rings and cone-shaped rings. Good application objects are for example the cyclones and the ducts of circulating bed boilers, carburetor plants, etc. various combustion chambers and high temperature devices. The concerned elements have special conditions concerning their tightness, so that their seam surfaces must be shaped so that they are profile surfaces differing from plane surfaces, profile surfaces having the capacity to resist to leakage through seam better than straight surfaces.

Abstract: A thermoplastic conformal tool/vacuum bag that is structured to substantially conform to a surface or a cavity in a composite structure is placed proximate to a uncured composite member to fabricate a composite structure. External heat and external pressure are applied to cure the member. The conformal thermoplastic tool/vacuum bag is removed from the cured assembly by reheating, if necessary, to facilitate removal of the tool/vacuum bag.