Abstract: A method provides for full or partial infusion of resin into three-dimensional, woven textile preforms. Resin film is placed at selected locations adjacent the preform, and the resin film may be separated from other areas of the preform using separator sheets or other materials. The preform is heated and may be vacuum-bagged to apply pressure, or may be rolled or fed through a die. The heat and pressure cause the resin to infuse into the selected areas of the preform adjacent the resin films. The amount of resin in the partial infusion is the same as is necessary to fully infuse the preform, but the resin remains localized in the selected areas until heated again at cure to cause the resin to flow throughout the preform. The method may also be used to fully infuse the preform with resin by providing sufficient temperature and time at that temperature during the initial infusion.

Abstract: For producing a structural component of fiber-reinforced material by a resin transfer molding process, a preform unit is inserted in a form tool including upper and lower metal molds enclosing the perform unit therebetween, without a seal between the molds. The preform unit includes a resin-impregnatable and curable preform body of reinforcing fibers, and an envelope that encloses the preform body and includes an envelope sleeve and closures with valves at the two ends thereof. The sealed envelope is evacuated around the preform body through one valve, and resin is injected through the other valve. The envelope prevents resin discharge from the unsealed form tool during resin impregnation of the preform body.

Abstract: An apparatus for fabricating fiber reinforced plastic structures is disclosed. In detail, 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: An apparatus for fabricating fiber reinforced plastic structures is disclosed. In detail, 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 there from. A resin distribution is positioned between the lay-up and the fluid impervious sheet. The resin distribution system includes a resin distribution medium for receiving resin from the inlet port and a resin containment layer between the resin distribution medium and lay-up for preventing resin flowing from the resin distribution medium into the lay-up until the resin distribution medium is substantially filled with resin.

Abstract: A method for producing fibre-reinforced plastic components made of dry fibre composite preforms by means of an injection method for injecting matrix material. Arrangement of the fibre composite preform (1) on one surface (11) of the preform (1) resulting in a flow promoting device (15), on a tool (3), creates a first space (10) by means of a gas-permeable and matrix-material-impermeable membrane (7) surrounding the preforms (1). Formation of a second space (27) situated between the first space and the surroundings by means of a foil (19) which is impermeable to gaseous material and matrix material, is provided, with removal by suction, of air from the second space (27) resulting in matrix material being sucked from a reservoir into the evacuated first space (10) and with the flow promoting device (15) causing distribution of the matrix material above the surface (11) of the preform (1) facing said flow promoting device (15), thus causing the matrix material to penetrate the preform (1) vertically.

Abstract: The invention relates to a method for the production of molded parts having a front face and a back face made of a hardenable reaction material, whereby a casting mold consisting of several mold parts is formed, said casting mold having a configuration that remains substantially unchanged during a molding and hardening step and forming a cavity into which the reaction material is filled and hardened, whereupon the casting mold is opened and the molded part is removed from the casting mold. At least one casting mold part has a deformable surface and the cavity of the casting mold is filled with a predetermined amount of hardenable reaction material from a reservoir. The reaction material is hardened while the volume of the cavity of the casting mold is reduced by deformation of the deformable surface of the casting mold.

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: Provided by the present invention is a mold release film for sealing a semiconductor element, which does not deform or cause deformation of the terminals of the semiconductor and which has good releasability during the semiconductor element sealing process, and a sealing method for a semiconductor element using the mold release film, which can improve efficiency of manufacturing a semiconductor.

Abstract: The present invention relates to an insert molding method for injection molding of resin or rubber at an insert set in a lower mold by injecting and filling melted resin or rubber into a cavity of an upper mold through a gate in a state where the upper mold and lower mold are disposed so as to be opposed to each other, and the invention relates to a metal mold therefor, wherein a movable supporting member having flexibility, on which the above-described insert is placed, is vertically movably disposed in a recess formed on the upper surface of the above-described lower mold, and the underside thereof is supported by the tip ends of shafts of a plurality of pressing means that independently operate, and the corresponding movable supporting member is moved while being pressed by the respective shafts of the corresponding pressing means to the upper mold at a plurality of positions, and molding is carried out in a state where the upper surface of the above-described insert is uniformly brought into contact with

Abstract: A method and apparatus 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 and curing the lay-up in an autoclave. 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 upward from the bottom surface. The predetermined distance varies along the length of the mold and generally conforms to the outer profile of the composite component to be fabricated. The caul is positioned over the lay-up and defines a longitudinal axis extending along the length of the caul and a lateral axis extending along the width of the caul.

Abstract: Processes and systems are provided to reduce sticking of graphite materials and particularly resin impregnated graphite materials to forming tools, such as an embossing roller, during a process of manufacturing articles from the graphite materials. In one embodiment, an aerosol spray non-stick material is intermittently sprayed upon the embossing rollers. In a second embodiment, one or more sheets of thin flexible solid non-stick material, such as polyethylene, are sandwiched between the graphite material and the embossing rollers. The system is particularly useful for manufacturing materials useful in producing components of fuel cells.

Abstract: A sheet of uncured polymer, which is preferably reinforced with multiple layers of fiber, is staged or partially cured to a state in which the sheet is rigid at room temperature. Multiple apertures are drilled into, and preferably through, the sheet. The apertures are for acoustic or laminar flow control, and include holes having diameters in the range of 0.025 to 0.120 inch. In the case in which the fabricated panels must conform to a particular shape, the perforated, partially cured panels are heated to a temperature at which the panel softens, and conformed to the desired surface. The partially cured, perforated sheets are then cured. In order to prevent closure of the drilled holes during the cure, the perforated panel is sandwiched between two layers of glass fabric and cured on an elastomeric tool surface which expands with increases in temperature, forcing the glass fabric to seal the holes during cure. Release coatings are used to aid panel/liner separation.

Abstract: A method of resin molding for molding regular products and a resin molding machine for the same. In the method of the present invention, release film, which is capable of easily peeling off from molding dies and resin, is provided on faces of molding dies. A member to be molded by the molding dies 15 is clamped together with the release film. An inner face of a pot of the molding die is covered with the release film. A resin tablet is supplied into the pot.

Abstract: A method of making an elastic pad for a sole in footwear has the following steps. Form an elastomer, a positioning rod is extended from the elastomer, the positioning rod supports and positions the elastomer in a mold. Form gasbags, by enclosing the elastomer with heated plastic film in mold then close the halves of mold. An elastic pad is then formed. Trim the elastic pad along the pressed periphery which is formed by the mold closure on excessive plastic film.

Abstract: A sculptor's pressure vessel having a frame, a pressure container and an expandable member for pushing the pressure container against a portion of the frame to seal the container. A pressurized gas supply is connected expandable member to inflate it and to push the pressure container against the top of the frame to seal the pressure container. The pressurized gas supply is also connected to the frame top to pressurize the pressure container when it is in sealed contact with the frame.

Abstract: This invention relates to a cushioned dust control mat or article wherein the mat comprises at least two distinct layers of rubber, one comprising foam rubber, the other comprising solid rubber and has a plurality of star-shaped protrusions in the upper surface thereof. Also, the surface of the mat between the protrusions is ribbed or recessed. The solid rubber layer is present over the foam rubber layer on the top side of the mat in which the plurality of star shaped rubber protrusions are present to provide cushioning characteristics. The solid rubber layer acts as a cap or barrier for the foam rubber layer, particularly over the star shaped protrusions, in order to provide a mat which is resilient, will not easily degrade in its modulus strength after appreciable use and/or washing within industrial cleaning processes, and will not exhibit appreciable cracking or breaking, particularly within the star-shaped protrusions, after standard use for pedestrian traffic.

Abstract: A thermal interface material for interfacing with at least a first surface. One embodiment of the thermal interface material includes a plurality of thermally conductive, malleable fibers arranged in a pattern. The fibers contact each other so as to reduce air gaps and fill irregularities when the fibers are compressed against the first surface.

Abstract: A method for manufacturing rubber plate having colored patterns thereon includes step 1: to prepare a heat transfer decal having a colored pattern thereon; step 2: to prepare a male mold and a rubber plate put on the male mold, the decal put on the rubber plate; step 3: to prepare a female mold having a recess defined therein, and step 5: to press the decal on the rubber plate between the male mold and the female mold at a high temperature. The pattern on the decal is printed on the rubber plate.

Abstract: A process for fabricating a face plate for a flat panel display such as a field emission cathode type display, the face plate having integral spacer support structures is disclosed. Also disclosed is a product made by the aforesaid process. The support structures are designed to be load bearing so as to prevent implosion of a planar, transparent face plate toward a parallel spaced-apart base plate when the space between the face plate and the base plate is sealed at the edges of the display to form a chamber, and the chamber is evacuated in the presence of atmospheric pressure outside the chamber. Unlike most spacer support structures proposed for such flat panel displays, the support structures are made from the same material as the substrate from which the face plate is fabricated. For a preferred embodiment of the process, a perforated laminar template is sealably sandwiched between a laminar silicate glass substrate and a manifold block to form a temporary sandwich assembly.

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: Method and apparatus for installing a liner material into a host conduit such as, e.g., a sewer pipe, hydrocarbon pipeline, gas line, water line, industrial chemical pipe, or a saltwater line. The liner material may include a compression liner and/or a preliner that is attached to the inner wall of the host conduit to repair or reinforce the host conduit or separate the host conduit from materials transported within the new liner formed from the liner material. Curable resin, slurry, or cement can be placed between the liner material and the host conduit to affix the liner material into place. Before and during curing, a fluid such as air or water can be used to inflate the compression liner outwardly toward the host conduit.

Abstract: In the method of resin molding of the present invention, air can be perfectly discharged from a specific area of a molding die including cavities, resin paths, pots, etc. so as to mold high quality products. The method comprises the steps of: covering a specific area of a molding die, in which air is left, with release film; clamping a work piece and the release film between an upper die and a lower die of the molding die so as to air-tightly seal the specific area; discharging the air from the sealed specific area; and filling a molding section with resin.

Abstract: A resin molding machine is capable of preventing molded products from forming resin flash on their surfaces. The resin molding machine includes a press section, a loading section, an unloading section, an accommodating section, a film feeding section, and an air sucking mechanism. By pressing the release film on the surface of the part of the work piece, the release film prevents the melted resin from invading into a gap between the release film and the work piece, so that no resin flash is formed on the surface of the work piece.

Abstract: A method of texturing fluoropolymer film and the textured product produced, which product retains the texture imparted after further processing, such as in thermoforming or molding processes.

Abstract: Under-fill molding is carried out by preferentially sending a sealing resin 22 under pressure into a clearance portion 21 between a semiconductor chip 6 and a substrate 2, and a molded component gate runner 25 that is connected to the under-fill portion 24 is separated at the substrate end position.

Abstract: The method of manufacturing semiconductor devices is capable of efficiently manufacturing semiconductor devices and preventing production of bad products. The method is executed in a molding machine including an tipper die and a lower die, in one of which a plurality of cavities corresponding to resin-molded parts of the semiconductor devices are formed. And, the method comprises the steps of: covering inner faces of the cavities and a parting face of one of the dies, which contacts a substrate of the semiconductor devices, with release film, which is easily peelable from the dies and resin for molding; clamping the substrate with the dies; filling the resin in the cavities; and forming the semiconductor devices by cutting the molded substrate.

Abstract: A minutely working method of and apparatus for opposing the surface of a transfer member having a concave or convex pattern formed on the surface thereof and the surface of a workpiece to each other, heating the transfer member and thermally expanding the transfer member in the direction of a normal to the surface thereof to thereby transfer the concave or convex pattern to the workpiece.

Abstract: In the method, after the pattern-bearing film is fed to the female mold, the distal end of the film is fixed under a lower portion of the female mold, and at the same time the film is retreated by a force from the film supply portion. Thus, this tightens up the film so that the slacks or wrinkles cannot be formed on the film. Therefore, the film can be fortunately spread around the parting surface of the female mold. In the apparatus, the film suppressing frame is pressed to the female mold through the sliding rod arranged in the female mold, in such a manner that the female mold embraces the frame. Thus, the pressing of the frame is performed by a simple structure, and the film is accurately positioned to the internal surface of the female mold. Also, the film suppressing frame is constituted to advance from and retreat to the female mold. Thus, this causes a space between the both molds and an outside standby position to be useless A space around the apparatus can be effectively utilized.

Abstract: The present invention relates to specific methods of producing cleated rubber-backed floor mats (such as dust control or rubber mats) through the utilization of the combination of a perforated coated woven fabric article and a cushioned platen liner between the article and the metal platen of an in-line dust control mat manufacturing machine. Such a procedure permits a more efficient manner of producing cleated anti-creep dust control mats than previously followed. In particular, the fabric article is in the form of a conveyor belt and is preferably constructed from Teflon®-coated woven fiberglass which will not adhere to the tacky rubber component of the target mat and can withstand the extremely high vulcanization temperatures and pressures required during the production of a dust control mat.

Abstract: A method of molding composite articles including arranging a pair of matched-tool mold sections in an opposed relationship, each mold section having a rigid housing and a thin, semi-rigid membrane removably and sealably mounted on the housing so as to define a fluid-tight chamber; filling the fluid-tight chambers with a non-compressible backing fluid; and accommodating thermal expansion of the backing fluid by an expansion chamber in fluid communication with the fluid tight chambers. The method further includes defining a mold plenum between the semi-rigid membranes when the mold sections are closed together; inserting reinforcement materials between the semi-rigid membranes prior to closing the mold sections; and injecting and curing a molding fluid after closing the mold sections.

Abstract: A process for fabricating a face plate for a flat panel display such as a field emission cathode type display, the face plate having integral spacer support structures is disclosed. Also disclosed is a product made by the aforesaid process. The support structures are designed to be load bearing so as to prevent implosion of a planar, transparent face plate toward a parallel spaced-apart base plate when the space between the face plate and the base plate is sealed at the edges of the display to form a chamber, and the chamber is evacuated in the presence of atmospheric pressure outside the chamber. Unlike most spacer support structures proposed for such flat panel displays, the support structures are made from the same material as the substrate from which the face plate is fabricated. For a preferred embodiment of the process, a perforated laminar template is sealably sandwiched between a laminar silicate glass substrate and a manifold block to form a temporary sandwich assembly.

Abstract: In accordance with the present invention, there is provided a process for forming a fiber-reinforced resin structure against a mold surface by vacuum bag forming. The process includes grooving the mold surface to form resin distribution conduits therein. A fiber-reinforced ply is distributed adjacent the mold surface. A flexible covering is placed over the fiber-reinforced ply and the mold surface to form a chamber therebetween. The chamber is evacuated. Resin is dispensed into the evacuated chamber such that the resin enters the resin distribution conduits and is thereby distributed about the ply.

Abstract: A process for the production of a resin piece by molding, places a self-demolding silicone membrane in a mold, and adds a catalyst to the resin to reduce the polymerization time of the resin so that the resin will not corrode the membrane.

Abstract: An apparatus for molding composite articles includes a pair of opposed matched-tool mold sections, each having a rigid housing and a thin, semi-rigid membrane removably and sealably mounted on the housing so as to define a fluid-tight chamber therein. The chamber of each mold section is filled with a noncompressible heat-conductive fluid to provide fluid backing to the portions of each membrane defining the molding surfaces of each mold section. A system of temperature control coils extending within each chamber are connected to an external heater/chiller unit to permit circulation therethrough of a suitable temperature control fluid, whereby positive control of the temperature of the backing fluid and, correlatively, the molding surfaces of the membranes.

Abstract: A method for fabricating composite structures is provided that includes providing a skin (20) that has at least one layer (160) of uncured composite material, and providing a flexible hinge tool (100) that has first and second tooling portions (110, 120) coupled with a flexible hinge (140). The first and second tooling portions (110, 120) of the hinge tool (100) each have a molding surface (112, 122), and the tooling portions (110, 120) are configured to form at least a portion of a stiffening member (10). The method further includes laying up at least one layer (160) of uncured composite material on the molding surfaces (112, 122) to form the stiffening member (10).

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: Cyanuric chloride moldings, especially tablets and flakes, have advantages over powders in ease of handling. The moldings are produced by droplet or strip application of molten cyanuric chloride on to a surface and dissipation of the latent heat of fusion by cooling the surface or contacting the melt applied as droplets or strips with a cooling gas.

Abstract: Hard tooling for consolidation of a workpiece there between is preserved for reuse by disposing between the tooling and a workpiece a plurality of distinct, superimposed sacrificial sheets, for example metal foils, to isolate the workpiece from the tooling. The sacrificial sheets are substantially non-adherent one to another; and a sheet in contact with a workpiece surface is substantially chemically non-reactive with such workpiece surface.

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 molded fabric treatment includes an integral undercut or inturned peripheral flange for affixing the treatment to the structure to be treated. The treatments have a conventional, decorative, woven polyester fabric (of the type currently used in conventional office divider screen systems), or fabrics comprising other synthetic or natural fibers, bonded with adhesive to a relatively stiff moldable non-woven polyester fiber backing. The treatments are formed in a membrane or bladder press in which a flexible membrane presses the fabric and fiber composite against a form or mold that includes an undercut edge which, in cooperation with the press membrane, forms undercut flanges about the periphery of the treatment. The undercut or inturned flange may then be "snapped" over a corresponding mounting lip on the structure to be treated.

Abstract: An abrasive article is provided having a sheet-like structure having a major surface having deployed in fixed position thereon a plurality of abrasive three-dimensional abrasive composites, each of the composites comprising abrasive particles dispersed in a binder and having a precise shape defined by a distinct and discernible boundary which includes specific dimensions, wherein the precise shapes are not all identical.

Abstract: The invention provides pressure-sensitive adhesive (PSA) coated articles, including tapes and transfer coatings, having microstructured surfaces and methods of making pressure-sensitive adhesive articles bearing such microstructured surfaces. The performance properties of the pressure-sensitive adhesive articles can be tailored by independently varying the microstructure and the rheological properties of the pressure-sensitive adhesive.

Abstract: A method by which an elastomer is applied to a model (1) with relief marks to be reproduced. The purpose of the elastomer once set is to form a mold membrane (14) and incorporate within its own material the shape of the marks on the model. The mold membrane is then separated from the model and filled with a setting material, and the mold membrane is applied to a support in order to transfer the marks after preliminary pasting.

Abstract: A process for fabricating a face plate for a flat panel display such as a field emission cathode type display, the face plate having integral spacer support structures is disclosed. Also disclosed is a product made by the aforesaid process. The support structures are designed to be load bearing so as to prevent implosion of a planar, transparent face plate toward a parallel spaced-apart base plate when the space between the face plate and the base plate is sealed at the edges of the display to form a chamber, and the chamber is evacuated in the presence of atmospheric pressure outside the chamber. Unlike most spacer support structures proposed for such flat panel displays, the support structures are made from the same material as the substrate from which the face plate is fabricated. For a preferred embodiment of the process, a perforated laminar template is sealably sandwiched between a laminar silicate glass substrate and a manifold block to form a temporary sandwich assembly.

Abstract: A resin molding method by which resin is filled into a cavity while an article to be molded is clamped between upper and lower molding dies, wherein a cavity indentation is formed from an end face of a cavity piece provided in a cavity hole formed in the molding piece and of an internal wall surface of the cavity hole, the method including the steps of: arranging the cavity piece provided in the lower molding die so as to be movable in a direction in which the molding dies are opened or closed; covering a parting surface of each of the resin molding dies with a release film; sucking the release film from an area in the vicinity of an inner bottom surface of the cavity indentation of the lower molding die, to thus form a storage section for storing resin used for a molding operation within the cavity hole; feeding a required amount of resin to the storage section; setting the article on the lower molding die and clamping the article between the resin molding dies; and pressing the cavity piece of the lower mol

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: The method of forming a light-weight, fiber-reinforced, particularly glass fiber-reinforced-thermoplastic resin product includes the steps of melting and mixing thermoplastic resin pellets containing parallely oriented fibers 2-100 mm long, injecting the melted resin into a cavity which is closed so that its volume is smaller than that of the final molded product, and, before or after the resin injection is completed, opening the cavity until its volume is equal to that of the final molded product. Unlike the conventional injection-molded products, this product does not require a foaming agent and, if it uses any, requires only a small amount of foaming agent. The product thus formed is light in weight and has fibers uniformly entangled inside, providing an excellent appearance of the surface. Further a skin layer is formed over the surface. These features combined with the reinforcement by the glass fibers offer high strength and high stiffness.

Abstract: An apparatus for molding composite articles includes a pair of opposed matched-tool mold sections, each having a rigid housing and a thin, semi-rigid membrane removably and sealably mounted on the housing so as to define a fluid-tight chamber therein. The chamber of each mold section is filled with a noncompressible heat-conductive fluid to provide fluid backing to the portions of each membrane defining the molding surfaces of each mold section. A system of temperature control coils extending within each chamber are connected to an external heater/chiller unit to permit circulation therethrough of a suitable temperature control fluid, whereby positive control of the temperature of the backing fluid and, correlatively, the molding surfaces of the membranes.

Abstract: A method for producing a custom insole for a foot of a user, the method including the steps of providing a preformed insole precursor, the precursor being constructed of a solid material which is storable in an undeformed state and which is compressible to a deformed configuration under pressure substantially at room temperature and which retains the deformed configuration after removal of the pressure, and pressing the foot on the insole precursor, thereby compressing the insole precursor and forming an insole with a configuration in accordance with the configuration of the foot.

Abstract: An apparatus and method for injecting corrosion control compound into a crevice or void such as pipe flanges featuring a corrosion control kit comprising a syringe injector having a detachable nozzle, a corrosion control compound, pipe tape and a mantle for heating the compound. Other optional items may be included in the kit. The method of the subject invention utilizes the apparatus, is cost efficient and easy to perform. The resulting seal formed between the flanges is easy to inspect and requires no maintenance.