Abstract: A prosthetic socket casting device includes a base with a forward side from which an expandable bladder surrounding a central casting area extends. The bladder includes a plurality of inner expandable chambers that generally extend along the length of the bladder interior and peripherally surround the central casting area. The inner walls of the chambers are formed of a pliable, fluid impermeable relatively thin sheet material that is distendable upon pressurization of the chamber volumes. The bladder further includes an outer covering or wall formed of a material or construction that limits distention of the bladder outwardly. The chambers may be expanded using pressurized air or other fluid to constrict the central casting area in which a residuum having a settable prosthetic socket material thereon may be placed for molding and curing under pressure. The multiple expandable chambers create a desirable pressure distribution circumferentially around the central casting area.

Abstract: This invention relates to a method for manufacturing a large FRP member including: disposing a preform containing a reinforcing fiber on a surface of a molding die; covering a molding portion with a bagging material or a mold and providing a suction port and a resin injection port for sealing; evacuating the molding portion through the suction port; heating the molding portion; injecting a thermosetting resin from the resin injection port for impregnating the reinforcing fiber with the resin while a temperature Tm of the molding die and a temperature Tv of the bagging material or the mold are both set to room temperature or more, and a difference ?T in temperature between the Tm and the Tv is set to 10° C. or less; and curing the resin by maintaining the molding portion at a predetermined temperature Tpc which is equal to or more than room temperature.

Abstract: A process for the production of composite tubing, particularly for air conditioning, from a structure of mineral or organic fibers, natural or artificial. The structure of fibers is impregnated with a suitable resin, and after shaping in or on a mold, the temperature and possibly the pressure is raised for polymerization of the resin, a sealing of the wall of the shaped piece being carried out in the course of this process. The structure of fibers is constituted by a single ply of a unit weight of at least about 400 g/m2, which ply is impregnated with resin at an impregnation quantity of at least 40%, then there is emplaced on one of the surfaces of the single ply a coating of a sealing agent. The polymerization is carried out while the single ply and its coating have the desired shape in or on the mold.

Abstract: The apparatus of the present invention is generally characterized by a heating/inflation module having pressurizable interior and an attached heat curable pre-preg. In particular, an elastomeric, seamless composite is provided that includes a heating element disposed within a thermoset resin matrix. The composite adapted to maintain a consistent temperature profile and an internal air pressure. A first end piece is attached to a first end of the composite and has an air port for communication with a compressed air source, a vacuum port for communication with a vacuum supply source and at least one electrical cable port for communication with a power supply source. A second end piece attached to a second end of the composite. The apparatus further includes a pre-preg removably attached to an outer surface of the composite. The pre-preg includes a structural fiber matrix supporting a heat curable resin.

Abstract: Tubular-shaped flexible members for air springs are made of rubber or rubber-like elastomers and are reinforced by reinforcement layers. In order that the air spring flexible member can roll telescopically off a roll-off piston, the tubular-shaped flexible member sections must be brought into a slightly conical or bottle-like configuration and then vulcanized in this form. A method forms and vulcanizes an air spring flexible member blank and utilizes an apparatus which includes a mold defining a bellied inner wall defining a common hollow space for receiving the air spring flexible member blank therein. A pressure bellows unit includes a pressure bellows extending axially in the common hollow space as well as first and second end pieces joined to the pressure bellows at corresponding longitudinal ends thereof.

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: 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 of forming a unitary, composite structural member, and a member formed in accordance with the process. The process involves stitching a plurality of warp knit panel sections together to generally form a plurality of independent panel sections. The sections are placed within the dies of a molding tool such that a rib portion of each section aligns. Inflatable bladders are then slipped into voids formed in between the various panel sections of the assembly. The bladders are inflated to hold with one another. Resin is then infused into the panels that make up the assembly. The assembly is then cured. When the panels are removed from the molding tool a unitary, complexly shaped, composite structural member is formed.

Abstract: A method is disclosed for reinforcement of thin wall hollow thermoplastic storage vessels with one or more wraps of continuous fibers. This method requires thermal bonding between the reinforcement fibers and the outer surface of the thermoplastic storage vessel while the interior cavity of the storage vessel is being pressurized. The fiber wraps can also be oriented in spatial directions further resisting internal stress on the storage vessel walls when put in service.

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: A method and an apparatus for making a pipe, and a pipe, wherein the pipe is made from a plastic feedstock pipe by expanding it against a mould. In the first step, that portion of the plastic feedstock pipe (4) which is to have a greater diameter than the rest of the pipe is partly expanded. Only after this is the entire plastic feedstock pipe (4) expanded against the mould (1).

Abstract: A method of manufacturing a honeycomb structure, the method comprising the steps of forming staggered cells through the entire thickness of a fiber fabric, causing loosely held pegs to penetrate into respective ones of the cells, each peg having a cross-section of size smaller than that of the corresponding cell and being made of a material that is suitable for expanding; expanding the pegs so that they fill the cells and exert pressure on the inside faces of the cells; and shrinking the pegs and then withdrawing them.

Abstract: A method for manufacture of a hollow complex three-dimensional fiber golf club head having at least one hole. A fluid-removable core is shaped in the general form of the golf club head, placed in a flexible pressurizable bladder around the core, at least one ply of fiber impregnated with a curable resin is wrapped over the core and bladder, and a cured part is formed by pressurizing the bladder while the core, bladder, and impregnated fiber is in a female mold to force the plies against the inner surfaces of the mold. After heating to cure the resin, the bladder and the fluid-removable core is removed from the interior of the cured part by disintegrating core with a fluid sufficient to allow removal of the bladder.

Abstract: This invention relates to a novel apparatus and process for producing thermoplastic articles. In one aspect, the invention pertains to a process for manufacturing fiberglass products using a fiberglass material consisting of fiberglass strands commingled with heat-formable polypropylene strands. A molding apparatus comprising: (a) an air pressure chamber with an open side; (b) a flange plate fitted to the open side of the air pressure chamber, said flange plate having an opening therein for receiving a mold; (c) an upper bladder associated with the flange plate and covering the opening; (d) a base pressure plate; (e) a mold positioned on the base pressure plate; and (f) a locking mechanism for securing the air pressure chamber with the base pressure plate, and balanced air pressure in each chamber during molding.

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: A composite sports racquet frame is made by placing a first prepreg tube into a first mold plate and a second prepreg tube into a second mold plate. A plurality of pin plates, each having a plurality of pins which are at least substantially parallel to one another, are secured to the mold plate so that, when the mold is closed, the pins extend between the two tubes. The tubes are pressurized to assume the shape of the mold and contact one another, and the mold is heated to allow resin to flow between the tubes as they cure, the pins forming pin holes in the frame. Once cured, the frame is removed from the mold, and the pins are withdrawn. If desired, the ends of the tubes forming the handle section can be kept separate from one another during the molding process, by using a removable mold plate. In this manner, not only do the two tubes become integral with one another, at least in the head portion, but string holes do not need to be drilled after the racquet is molded.

Abstract: For the purpose of fastening cables to the inner wall of a non-accessible waste-water pipe, an internal liner has been developed, which is constructed from at least two layers, the first layer, which rests against the internal wall of the pipe when in the laid condition, having a profile or empty spaces for receiving cables, and a second layer, of envelope-like type, which carries the first layer.

Abstract: A method of forming a unitary, composite structural member, and a member formed in accordance with the process. The process involves stitching a plurality of warp knit panel sections together to generally form a plurality of independent panel sections. The sections are placed within the dies of a molding tool such that a rib portion of each section aligns. Inflatable bladders are then slipped into voids formed in between the various panel sections of the assembly. The bladders are inflated to hold the panel sections in the shape of the final product and to hold the rib portions in contact with one another. Resin is then infused into the panels that make up the assembly. The assembly is then cured. When the panels are removed from the molding tool a unitary, complexly shaped, composite structural member is formed.

Abstract: A work table supports a grid of green brick aligned in longitudinal and transverse row for indexing movement by a hydraulic cylinder actuated pusher. The brick are indexed longitudinally beneath a first transverse row of embossing devices in a transverse row aligned with one embossing device being over every other brick of the transverse row. Following actuation of the first transverse row of embossing devices the brick are indexed beneath a second transverse row of embossing devices each of which is aligned with the brick that were not embossed by the first transverse row of embossing devices. Ramps are provided below the rows of embossing devices to elevate the brick above the next adjacent rows so that the brick being embossed is at a higher elevation than the adjacent brick.

Abstract: A method for fabricating a wing having a hinge member, including: a step for preparing a dry preform for a skin portion and a spar portion; a bladder bag arrangement step in which a tube-like bladder bag is inserted into a front hollow portion formed within a wing with the hinge member fixed on a predetermined position thereof, the bladder bag having flexibility and fluid-sealing performance, the hinge member getting close contact with the spar portion; a step for enclosing the dry preform together with the hinge member and the bladder bag into a molding jig having a shape of cavity; a step for impregnating the dry preform with a liquid resin, by introducing the liquid resin into the cavity with applying a pressure to the inside of the bladder bag; and a step for heating and setting the liquid resin impregnated in the dry preform.

Abstract: A method for producing a bicycle wheel rim having an inner peripheral wall, an outer peripheral wall, two lateral walls joining said peripheral walls, and two circumferential wings, for anchoring a tire, is provided. The method providing a rim made of a single part made of structural fiber based material, preferably carbon fiber material.

Abstract: The present invention relates to a method for manufacturing a large FRP member and has the following structure.

Abstract: A method and a mask have been optimized to reduce seam lines in replicated structures using lithographic processes. Multiple exposures and sweeps across a substrate using the mask results in the reduction of seam lines in the final developed photosensitive or micro formed structures.

Abstract: A system for producing composite or bonded metal components including: first and second pressure chambers, each pressure chamber having an elastically deformable chamber wall; means for circulating fluid at an elevated temperature and pressure through each said pressure chamber; and at least one mould assembly including at least one separate mould section providing a mould cavity within which a composite or bonded metal lay-up can be located; wherein when the system is in use, the pressure chambers are held together with the elastically deformable chamber walls located in opposing relation, the at least one mould assembly containing a said lay-up being accomodated between the chamber walls while fluid at elevated temperature and pressure is circulated through each pressure chamber such that the lay-up can be compressed and cured or formed.

Abstract: A method for manufacturing a composite structure is disclosed herein. The process uses a frame and selectively pressurizable forms. The forms define the interior members of the composite structure and frames define the exterior surface of the composite structure. Composite material is wrapped around the forms and the forms and composite material are placed in the frame. Selective forms are then pressurized and the composite material is co-cured together. A single piece co-cured fuselage incorporating a plurality of stiffeners is also disclosed in the application. The stiffeners are co-cured to the fuselage and may be in various patterns. The patterns may include an iso-grid pattern, and ortho-grid pattern, and a hoop-grid pattern.

Abstract: An apparatus and method are provided for thermoplastically forming a contour in a thermoplastic duct defining a passage. The apparatus includes a longitudinal collar that defines a cavity and a rigid inner support structure extending longitudinally in the cavity. The collar and/or the inner support structure define a mold contour. One or more heaters are configured to heat at least a formation portion of the duct to a formation temperature. An expansion member, such as an expandable elastomer, which is disposed between an inner surface of the collar and an outer surface of the inner support structure, is configured to urge the formation portion of the duct against the mold contour to thermoplastically form the duct.

Abstract: A method of molding a hollow, reinforced molded plastic article. A preform is provided in the shape of the article to be molded. The preform comprises randomly commingled, short lengths of thermoplastic and reinforcing fibers loosely bonded together. A core is provided within the preform and may either be a flexible inflatable core which may be removed later or a thermoplastic liner. The preform is placed in a mold and heated to fuse the thermoplastic while a pressurized liquid coolant is circulated within the core.

Abstract: The invention is a method of making a foam filled honeycomb core structure comprising the steps of: 1) providing a honeycomb core billet; 2) reinforcing the honeycomb core with foam; 3) placing the foam filled billet in mold having a curved mold surface; 4) creep forming the foam filled billet to the general shape of the structure by applying a load to the foam filled billet; and 5) machining the creep formed billet to the actual shape of the structure.

Abstract: An apparatus for fabricating fiber reinforced plastic structures is provided. The apparatus includes a mold surface upon which can be supported a lay-up of one or more layers of a fibrous material, and over which can be placed a fluid impervious outer sheet with an inlet port and having its edges marginally sealed upon the mold surface to form a chamber. A vacuum outlet is connected to the chamber for drawing a vacuum therefrom. A resin distribution system is positioned between the lay-up and the fluid impervious sheet. The resin distribution system includes a distribution sheet for receiving resin from the inlet port and at least one flat resin distribution line connected to the inlet port.

Abstract: A method and apparatus for molding composite articles can include a pair of opposed hollow mold sections having first and second molding membranes which define a mold plenum therebetween. Each mold section can be filled with a substantially noncompressible, thermally conductive fluid. The temperature of the mold plenum can be controlled by regulating the temperature of the thermally conductive fluid. Sensing of various parameters during the injection and curing processes of the molding fluid, for example pressure, flowrate, temperature and filling of the plenum can be used to optimize the molding process.

Abstract: A method of installing a formed-in-situ repair in a pipe 40 comprising locating a sleeve of reinforcement material impregnated with a settable resin within a tube 36 of soft, impervious sheet material; everting the tube into said pipe such that the sleeve is carried into a desired zone and brought into intimate contact with its inner surface; guiding the point of eversion 43 of said tube through directional changes in the pipe with guiding means 21; maintaining the inflation of the everted tube while passing a heated fluid medium through its interior to accelerate curing of the settable resin; and, when the settable resin is cured, de-everting the tube with withdrawal means 19 and withdrawing it from the pipe, leaving the sleeve of reinforcement material in place within it.

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.

Abstract: A method for relieving pressure in a vulcanized tire while still in a tire press is disclosed, wherein the bladder securement mechanism utilizes a position sensor mechanism and eliminates the need for spacers and a floating piston. A tire press comprises a lower mold, an upper mold, and a bladder securement mechanism. The bladder securement mechanism has an upper clamping mechanism for securing the upper periphery of a bladder and a lower clamping mechanism for securing the lower periphery of the bladder. A center mechanism tube has a center mechanism rod positioned therein. A piston is disposed within the center mechanism tube. The piston provides reciprocating motion to the center mechanism rod. A position sensor mechanism operatively associated with the bladder securement mechanism.

Abstract: One or more electric and/or data transmitting cables are confined in an elongated strip-shaped body containing a hardenable resin or the like, and the body is placed against a portion of the internal surface of an underground sewage, water or other pipe. An expandible tubular liner is thereupon introduced into the pipe and is expanded to press the body against the pipe. The body is caused to set, by conveying a hot fluid through the liner and/or by electrically heating the cable or cables, and to adhere to the internal surface of the pipe. The liner can remain in the pipe and can be bonded to the strip-shaped body and/or to the remaining portion of the internal surface of the pipe. Alternatively, the liner is caused to collapse and is withdrawn from the pipe once the strip-shaped body is bonded to the internal surface of the pipe.

Abstract: A process of fabricating a composite vessel includes the steps of: A) fabricating a thermoplastic liner for the vessel; B) overlaying a layer comprising fiber and a thermoplastic material (preferably by winding commingled filaments, rovings or yarns) onto the thermoplastic liner to obtain a composite intermediate structure (the fiber and thermoplastic material can be heated if desired during the overlaying, e.g. winding, step); C) heating the composite intermediate structure in a mold while applying at least one force thereto tending to urge the composite intermediate structure against and into the shape of the interior walls of the mold; D) continuing step C) until the thermoplastic liner and the overlaid layer consolidate to form a composite vessel; E) cooling the mold and composite vessel until the composite vessel is solidified; and F) removing the formed composite vessel from the mold.

Abstract: A process for fabricating a boat shell having a hull and deck molded together as a unitary piece in a single molding step is provided. A two part mold is provided including a first and a second mold half. Prior to molding the two halves are separated and materials which are used to form the inner layer, core and outer layer of the shell, are laid up within each half. Cooperative inserts are also removably secured to opposing upper and lower edges of the first and second mold halves. The inserts are then removed, a vacuum is created within the mold, and the shell is heated until cured. By overlapping and curing the port and starboard sides, the two sides become molded in a permanent manner such that the deck and hull of the boat are formed together as a unitary boat shell in a single molding step.

Abstract: A method of manufacturing a resin impregnated article includes the steps of providing a mold onto which a reinforcing material is placed, sealing the reinforcing material with an impervious sheet and regulating the pressure on the material and temperature of the material and resin by placing a fluid in contact with the impervious sheet and regulating the pressure and temperature of the fluid.

Abstract: A green ceramic core or other article at elevated temperature is placed between a complaint member and a relatively rigid setter while the green core or article cools to a lower temperature. The compliant member can comprise a fluid pressurized compliant bladder or a compliant, non-rigid setter or facing layer thereon for contacting a side of the green core or article.

Abstract: Apparatus according to a disclosed embodiment are provided for molding a unit of a second material onto an article made of a first material. An inflatable, flexible bladder is fluidly connectable to a source of a pressurized fluid, such as compressed air. The pressurized fluid is used to inflate the bladder such that, when the bladder is at least partially inflated with the fluid, the article may be pushed against the bladder to invert the bladder and cause the exterior surface of the bladder to form a mold around at least a portion of the article.

Abstract: A method of manufacturing a resin impregnated article comprises the steps of providing a mold onto which a reinforcing material is placed, sealing the reinforcing material with an impervious sheet and regulating the temperature of the reinforcing material and resin by placing a fluid in contact with the impervious sheet and regulating the temperature of the fluid.

Abstract: A molded article includes a matrix of transparent plastics material incorporating a filler that is essentially constituted by fibers, the filler comprising 1% to 25% by mass of the mixture and the mean length of the fibers constituting the filler lying in the range of 100 &mgr;m to 700 &mgr;m.

Abstract: Disclosed is a method for manufacture of a hollow complex three-dimensional fiber golf club head having at least one hole. The method involves shaping a fluid-removable core in the general form of the golf club head, placing a flexible pressurizable bladder around the core, wrapping over the assembly of core and bladder at least one ply of fiber impregnated with a curable resin, forming a cured part by pressurizing the bladder while the assembly of core, bladder, and impregnated fiber is in a female mold to force the plies against the inner surfaces of the mold, such that compaction of the fiber against the inner surfaces of the mold is from the pressurization of the bladder and not from the core, and heating to cure the resin, removing the bladder and the fluid-removable core from the interior of the cured part by first disintegrating and removing the fluid-removable core with a fluid sufficient to allow removal of the bladder.

Abstract: A process, and the product thereof, for making a composite vessel having at least one closed end, the process including the steps of: fabricating a thermoplastic liner for the vessel; overlaying onto the liner a layer of commingled fiber and thermoplastic material to obtain a composite intermediate structure; pressing and heating the composite intermediate structure to effect at least partial consolidation in apparatus which includes upper and lower silicon rubber bags, the bags having dimensions such that, during operation, their facing peripheral regions abut to encompass the composite intermediate structure; then placing the composite intermediate structure in a mold; heating the composite intermediate structure in the mold while applying a force, such as internal gas pressure, tending to urge the composite intermediate structure against and into the shape of the interior walls of the mold until the thermoplastic liner and the overlaid layer fully consolidate; cooling the mold and composite vessel until th

Abstract: A transverse leaf spring structure and a manufacturing method for a composite transverse leaf spring is disclosed. The leaf spring is formed using a pre-formed tubular fiberglass fabric comprising longitudinally aligned and braided fiberglass fibers. The fabric is installed over an interior form, such as one or more inflatable bladders, and positioned within a forming mold. After resin is applied and cured to an appropriate stiffness within the mold, the mold is removed. The interior form is then removed from the composite leaf spring.

Abstract: Bicycle frame components without laps made by a method comprising; shaping a fluid-removable core in the general form of the component, placing a flexible inflatable bladder around the core, wrapping over the assembly of core and bladder at least one ply of fiber impregnated with a curable resin, forming a cured part by inflating the bladder while the assembly of core, bladder, and impregnated fiber is in a mold to force the plies against the inner surfaces of the mold, such that compaction of the fiber against the mold is predominantly from the bladder inflation and not from the core, and heating to cure the resin to form a cured part, removing the bladder and the fluid-removable core from the interior of the cured part by disintegrating the fluid-removable core with a fluid sufficient to allow removal of the core and the bladder.

Abstract: A method of molding a hollow, reinforced molded plastic article. A preform is provided in the shape of the article to be molded. The preform comprises randomly commingled, short lengths of thermoplastic and reinforcing fibers loosely bonded together. A core is provided within the preform and may either be a flexible inflatable core which may be removed later or a thermoplastic liner. The preform is placed in a mold and heated to fuse the thermoplastic while a pressurized liquid coolant is circulated within the core.

Abstract: A method is for forming a plastic protective package for an electronic device integrated on a semiconductor and comprising an electronic circuit to be encapsulated in the protective package. The electronic device may be at least partially activated from outside of the protective package. The method may include providing a mold having a half-mold with an insert abutting towards the inside of the mold and an end having an element that can be elastically deformed to abut in pressing contact against at least one portion of the integrated circuit. The method may also include injecting a resin into the mold so that the protective package has a hole by the at least one portion of the electronic circuit.

Abstract: A definitive socket for residual limb prosthetic use is formed in a single molding step by compressive pressure casting or molding a pre-formed, moldable, hardenable socket material over a residual limb and curing the socket material to a load-bearing hardened condition while it is maintained under peripheral compressive pressure against the residual limb and while the residual limb is tensioned in a distal direction during the casting process. The combination of pressure casting the socket material and applying tension to the residual limb in a distal direction while the socket material is curing results in forming a definitive socket that fits well to the residual limb after curing without substantial rectification. Pressure relief formations, socket coverings, and a prosthesis coupler may be compression molded simultaneously with the socket.

Abstract: An improved shaft for a golf club and methods of manufacturing the same. One or more layers of a loaded film are used to define in part the overall weight, swing weight, and/or balance point of a golf club shaft, without significantly affecting the flexibility and/or torsional characteristics of the shaft. A set of plies of pre-preg composite fiber sheet and loaded film may be wrapped in a predetermined manner around a mandrel, placed in a mold, and heated for a predetermined period of time to form a shaft for a golf club.

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 infiltration. 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.