Abstract: A method is described for manufacturing an item of terry cloth that incorporates a decorative panel. The item of terry cloth is woven with a panel that is loopless and double-sided. At least one face of the panel is formed of a synthetic fusible fiber. The fusible fiber is at least partially fused by applying heat and pressure to the face of the panel, thereby forming a smooth patterned surface on the face of the panel.

Abstract: Glass matt reinforced thermoplastics suitable for the production of paintable parts, comprisinga) a thermoplastic matrix polymer of a viscosity under processing conditions corresponding to a melt flow index (MFI 230/2.16) of polypropylene of at least 250 g/10 min andb) one or more glass matts which, upon heating, bring about an expansion of the glass matt reinforced thermoplastics to at least 2.5 times the original thickness, optionally in combination withc) an addition of fine-particle, mineral fillers.

Abstract: A filter element made of nonwoven filter fabric includes a plurality of pleated portions and a flange portion formed integrally with the filter portion. The flange portion is formed by a pair of press-forming dies to have a thin and compressed connecting portion formed along the outer periphery of the filter portion, a thick and uncompressed seal portion formed along the outer periphery of the connecting portion and a thin and compressed protecting portion formed along the outer periphery of the seal portion.

Abstract: A waterproof felted material (10) has a thermoplastic polyolefin sheet (20) to which a thermoplastic fibrous polyolefin matting (30) is bonded with a portion of the fibers of the matting (40) embedded in and fused to the thermoplastic polyolefin sheet. A solidifying coating (50) may be applied to the matting.

Abstract: A screening screen assembly for a vibratory screening machine including an apertured plate or frame, and a bonded subassembly of an undulating support screen and fine screening screen and finer screening screen bonded to each other by a fused plastic grid and bonded to the apertured plate or frame. A method of fabricating a screening screen assembly for a vibratory screening machine including the steps of providing a support screen, superimposing a plastic grid onto the support screen, superimposing a finer screening screen onto the fine screening screen, applying heat and pressure to the superimposed screens to fuse the plastic grid and thereby form a flat bonded laminate subassembly by causing the fused plastic grid to permeate the fine screen and the finer screen and the support screen, forming the bonded laminate subassembly into an undulating shape, providing an apertured plate or frame, and bonding the undulating bonded subassembly to the apertured plate or frame.

Abstract: A coreless roll of product that is self-supporting in a rotary dispenser. The roll includes a rolled web of product that is wound throughout its diameter about a winding axis into a cylinder having first and second flat ends. At least one flat end defines a mounting hole at substantially the center of the winding axis of the coreless roll. The mounting hole has a depth and has sides generally perpendicular to the end of the roll. The sides are separated by a distance that is less than the depth of the hole such that the mounting hole is adapted to receive a plunger from a rotary dispenser. Methods of making the coreless roll are also described.

Abstract: A process of making a molded laminar structure from a reinforced fibrous mat impregnated with an uncured thermal setting resinous binder wherein the mat is compressed and molded, the binder cured to form a shell, a covering secured to one surface of the shell to form a laminar structure, and trimming the laminar structure to predetermined dimensions.

Abstract: A composite component is provided having at least one felt layer as reinforcement when used for crash and/or noise management applications, and preferably also including at least one reinforcement fiber layer. At least one of the reinforcement layers, preferably a felt layer, may be formed into a preform which is placed into a mold of suitable shape to form the component, along with the other reinforcement layers, with a resin/polymer being injected into the mold and then cured to form the composite component.

Abstract: As a paper-made stampable sheet having a high rigidity and, if necessary, improved adhesiveness and non-permeability and a light weight stampable sheet shaped body made from this sheet and a method of producing the same, there are proposed a paper-made stampable sheet obtained by paper-making a mixture of thermoplastic resin and reinforcing fibers to obtain a sheet-like web, piling a thermoplastic resin film of a single layer or multi layer or an organic fiber nonwoven fabric having at least one excellent property selected from rigidity, non-permeability and adhesiveness on at least one-side surface of the sheet-like web in accordance with use purpose, compressing them under heating above a melting point of the thermoplastic resin constituting the web, cooling and solidifying at a compressed state as well as a light weight stampable sheet shaped body made from this sheet and a method of producing the same.

Abstract: The present invention relates to a method of compacting a plurality of flat, stacked, non-woven cotton and cotton blend articles from a normal size to a greatly reduced size to form a package of such articles that saves exterior packaging, shipping, handling and warehouse costs. The pressure and time dwell are selected to compact the stacked articles to the extent necessary to cause the desired size reduction, but not sufficient to either damage the articles or compact them to the degree that a liquid or other means is required to recover them from their compacted to their original size.

Abstract: A high pressure laminate is made of several layers of paper, including from bottom to top core sheets, a decor sheet and an overlay sheet. The core sheets are either composed of cellulose fibers or composed of 30 to 90 weight percent cellulose acetate fibers and 70 to 10 weight percent cellulose fibers. The core sheets are respectively coated with either a lamination polymer or a plasticizer. The decor sheet is composed of a mixture and a conventional amount of paper making dye. The mixture comprises 30 to about 90 weight percent cellulose acetate fibers, 10 to 70 weight percent cellulose fibers and 0 to 20 weight percent fillers. The decor sheet is coated with a plasticizer. The overlay sheet is composed of cellulose fibers and is coated with a lamination polymer. Upon application of heat and pressure to the several layers a laminate is formed having thermoplastic properties, improved postformability and a significant reduction in the release of volatile organics during formation.

Abstract: A process for eliminating post-molding fabric curl and distortion in molded fabrics and fabrics produced thereby. The molded fabrics are laminates including a non-woven fabric face and a binder layer and/or sheet backing. Post-molding curling and distortion can be eliminated by maintaining heat on the face fabric until the backing has been cooled enough to be rigid.

Abstract: An enclosure for electronic modules, comprising walls made of composite material including conductive fibers for shielding the enclosure interior from electromagnetic radiation, and means for securely mounting at least one module inside the enclosure with a fastener means, the mounting means comprising composite material.

Abstract: An improved tackifier for making tackified substrates contains: (a) at least one epoxy resin, and (b) at least one curing agent for the epoxy resin, but (c) no catalytic amount of catalyst for the reaction between the epoxy resin and the curing agent. The tackified substrates are used to make composites by: (1) placing one or more of the tackified substrates in a mold; (2) injecting into the mold a matrix resin formulation which is chemically-similar to the tackifier, except that it contains a catalytic amount of catalyst for the reaction between the epoxy resin and the curing agent; and (3) curing the matrix resin formulation. The tackifiers are more storage-stable than similar tackifiers which contain catalyst, and the resulting composites have and/or retain physical properties better than composites made using tackifiers without curing agent.

Abstract: A molded article of a fiber-reinforced thermoplastic resin which suffers less deformation and has good appearance is produced by a method which includes the steps of:supplying at least two porous fibrous sheets,supplying a resin melt of a thermoplastic resin in a space between the porous fibrous sheets, andforcing the resin melt to fill the pores of the porous sheets by resin supplying pressure and/or pressing pressure and to reach outer surfaces of the porous fibrous sheet.

Abstract: Methods and apparatus for rapidly drying and compacting wet fiber mats are disclosed. Rapid drying is produced by heating the wet fiber mats with a combination of radiowave energy and conductive heating. As the fiber mats are heated, three-dimensional compacting forces are applied by pressing the fiber mats between a flat surface press and a porous support on which is mounted a resilient mold insert. At high radio frequencies in the microwave range, power is transmitted from a multimode cavity through the porous support and resilient mold insert to the fiber mat. At low radio frequencies, differential radio-frequency voltages are applied directly to metal press plates which contain and compact the fiber mat. Methods and apparatus can be adapted to conveyorized or multi-opening press operations. Objects suitable for use with the invention are most commonly characterized by having a flat face surface on one side and webs or other features which may extend normal or generally normal to the flat surface.

Abstract: A condensed mat of glass fibers incorporating a thermosetting resin is expanded over a mold. Gripping elements at the edges of the mold hold the edges of the expanded mat in place while a second mold confines and deforms the expanded mat between the two molds. Hot air is passed through the porous molds and through the expanded mat to set the thermosetting resin which thereby holds the expanded mat in its deformed shape to form a panel.

Abstract: A method of manufacturing a multi-holed plate made of a composite material wherein a molding resin is filled, with a resin membrane being applied inbetween, in the previously prepared holes of a raw forming element of the composite material and the raw forming element of the composite material is hardened by heat and pressure.

Abstract: A process is disclosed for producing reinforced twin-sheet thermoformed articles comprising the steps of heating first and second sheets of thermoplastic material; forming the sheets in molds; heating a reinforcing insert of thermoplastic material; placing the heated insert on the first sheet in its mold at the location to be reinforced; pressing the second sheet into contact with the heated first sheet and the heated insert to form the insert between the sheets so that a fusion of the thermoplastic sheets and the insert takes place to produce a reinforced section of the article having a desired shape and thickness. Alternative processes are disclosed wherein a heated quantity of thermoplastic liquid material is extruded or injected between the first and second sheets within the first and second molds either by inserting the liquid material before the molds are closed or by injecting it through one of the molds.

Abstract: A method of manufacturing a diaphragm of a speaker includes the steps of: 1. weaving a plurality of fibers to become a fiber sheet; 2. immersing the fiber sheet in resins; 3. spraying or inserting an enforcement material to the fiber sheet to form a combination sheet; 4. rolling the combination sheet into a flat pattern and therefore creating a tension therein; 5. drying the combination sheet, 6. putting said combination sheet into a mold and applying a high temperature thereto under a high pressure to form a cup-like configuration and 7. cutting the combination sheet into a desired configuration.

Abstract: A housing lining for a piston engine, drive motor, or machine composed of a sound-absorbent layer of fibers. The fibers are compressed and glued to form an essentially pore-free supporting frame at least in the vicinity of the edge of the layer.

Abstract: A process is disclosed for producing reinforced twin-sheet thermoformed articles comprising the steps of heating first and second sheets of thermoplastic material; forming the sheets in molds; heating a reinforcing insert of thermoplastic material; placing the heated insert on the first sheet in its mold at the location to be reinforced; pressing tile second sheet into contact with the heated first sheet and the heated insert to form the insert between tile sheets so that a fusion of the thermoplastic sheets and tile insert takes place to produce a reinforced section of the article having a desired shape and thickness. Alternative processes are disclosed wherein a heated quantity of thermoplastic liquid material is extruded or injected between the first and second sheets within the first and second molds either by inserting the liquid material before the molds are closed or by injecting it through one of the molds.

Abstract: A method for the manufacture of low cost "oriented" composite molding compounds using discontinuous fibers embedded in a resin matrix. The method involves the steps of aligning discontinuous fibers by use of a strong electric field while simultaneously inserting the fibers onto a polymer substrate comprised of an uncured resin matrix. A preferred embodiment includes the incorporation of a mesh or a glass capillary array located parallel and adjacent to the polymer substrate to further ensure fiber alignment. After the fibers are attached to the uncured resin matrix, the aligned fibers are forced to lie down parallel along the surface of the polymer substrate by mechanically forcing the fibers flat. The newly formed reinforced polymer films may then be stacked with the fibers of each ply oriented to achieve the desired mechanical properties, and then cured to produce an improved composite laminate which can be machined to form a high strength shaped member.

Abstract: An extensible composite fabric including a multiplicity of continuous fibers extending in one direction and distorted into aligned, locally parallel, curved paths for imparting extensibility to the fabric in that direction, and a method and apparatus for making such a composite fabric.

Abstract: A limited pressure expansion material that includes a plurality of microspheres uniformly dispersed throughout a thermally expansive material such as silicone rubber. Upon heating within a sealed curing device such as an autoclave, the pressure rise of the thermally expansive material is reduced near the pressure at which the microspheres begin to implode.

Abstract: A spring member made of a carbon fibers/carbon composite material in which carbon fibers are dispersed in a matrix of graphite, and a process for producing such a spring member. The process includes the steps of: (a) forming raw preformed yarns; (b) shaping the raw preformed yarns in a form of a yarn member, a taper member or a sheet member; (c) coiling the thus shaped member around a core rod together with a coiling spacer; (d) molding the coiled member by hot pressing at about 300.degree. C.-2000.degree. C. under a given pressurized pressure; and graphitizing the coiled member at 1500.degree. C.-3000.degree. C., after carbonizing at 700.degree.-1200.degree.C. if necessary.

Abstract: The invention relates to a resin transfer molding preform binder resin that comprises at least one aromatic polyepoxide, a fluorene epoxide that is different than the aromatic polyepoxide and having a defined structure, and a 9,9-bis(aminophenyl)fluorene curing agent. The binder resin is a solid, room temperature stable, essentially nonsintering powder that displays a glass transition temperature greater than about 40.degree. C. Also disclosed are preforms made with the binder resin and a method for preparing the preforms.

Abstract: A method of manufacturing three-dimensional parts using sheets of a thermoplastic resin high-performance fiber-reinforced composite material includes the steps of supplying the sheet of the high-performance resin-reinforced composite material which uses as a matrix a thermoplastic resin and in which reinforcing fiber is oriented, clamping an end portion of the sheet by a sheet clamping device, conveying the sheet to a heating/forming zone, heating the sheet to a predetermined temperature, clamping the sheet by upper and lower frames by driving cylinders, forming the three-dimensional part by operating a mold and thereby deep drawing the clamped sheet inwardly according to a stroke of the mold, and repeating the above-described series of steps continuously.

Abstract: This method for forming a measuring diaphragm which measures the volume of a passing gas with high accuracy and has a prolonged service life because the diaphragm moves completely in the same way to both sides of the measuring vessel in which it is fixed. The measuring diaphragm when produced in quantity has an undulating structure of high uniformity and variation in quality of the diaphragm is small.

Abstract: A screening screen assembly for a vibratory screening machine including an apertured plate, and a bonded subassembly of an undulating support screen and fine screening screen and finer screening screen bonded to each other by a fused plastic grid and bonded to the apertured plate. A method of fabricating a screening screen assembly for a vibratory screening machine including the steps of providing a support screen, superimposing a plastic grid onto the support screen, superimposing a finer screening screen onto the fine screening screen, applying heat and pressure to the superimposed screens to fuse the plastic grid and thereby form a flat bonded laminate subassembly by causing the fused plastic grid to permeate the fine screen and the finer screen and the support screen, forming the bonded laminate subassembly into an undulating shape, providing an apertured plate, and bonding the undulating bonded subassembly to the apertured plate.

Abstract: The present invention relates to a method of compacting to form a package of such articles that saves exterior packaging, shipping, handling, and warehouse costs. The pressure and time dwell are selected to compact the stacked articles to the extent necessary to cause the desired size reduction, but not sufficient to either damage the articles or compact them to the degree that a liquid or other means is required to recover them from their compacted to their original state.

Abstract: A strong, lightweight composite material having beneficial flexing characteristics is made using a unique reinforcement material. The reinforcement material comprises a fabric incorporating glass rovings with graphite tows in an architectural combination that retains the properties of both materials. Composite structures made using this reinforcement material with a thermosetting or thermoplastic matrix are extremely lightweight, with desirable anisotropic flexing properties. The finished composite structure is extremely useful as an arch support in a shoe to absorb and distribute the forces generated by walking. In distributing forces on the foot such a support will provide the desired stiffness along the longitudinal axis while allowing increased flexibility along the transverse axis.

Abstract: A method for shaping a trim cover fabric for the entire front surface of a vehicle seat back portion or the entire top surface of a vehicle seat cushion portion, includes providing a forming tool having a forming surface with a portion complementary to a basic shape to be provided for the seat surface and a portion defining a cavity; providing a plurality of style line inserts, different ones of the style line inserts having different styling surfaces that are complementary to different desired stylized shapes to be provided for the seat surface; selecting one of the style line inserts and inserting the selected style line insert into the cavity; positioning the trim cover fabric on the forming tool assembly; providing a pressing tool having a surface formed to be complementary to the forming surface of the forming tool and the styling surfaces of the plurality of style line inserts to enable the pressing tool to be used with a forming tool assembly that includes any of the style line inserts; and pressing th

Abstract: A molding method for molding a shaped plastic trim panel from a wet moldable composite includes a blade for trimming the molded plastic trim panel while it is still in the molding apparatus. The lower mold member has an annular severing slot and annular clamping shoulders inwardly and outwardly of the severing slot. The upper mold member has an annular slot that is aligned with the severing slot of the lower mold member and annular clamping shoulders on either side of the slot. These shoulders cooperate with the clamping shoulders of the lower mold member to clamp the margin of the molded plastic trim panel that is shaped in the molding members. An annular cutting blade having a serrated cutting edge disposed in the slot of the upper mold member moves down vertically into the severing groove to cut through the clamped margin and trim the molded plastic trim panel.

Abstract: The present invention essentially relates to a process for curing pipe insulation, including the employment of a two-part mold and the utilization of a device for the passage of curing air through the mold and through a pipe insulation preform which is arranged around a core disposed within the mold. The process for the curing of insulating chutes constituted of a fibrous materials, such as wool or the like, completely avoids the formation of any burrs which can conceivably be formed between interengaging and cooperating mold halves, one of which is a female and the other a complementary male component. A sharp and flexible leading edge in the male part is arranged to come into contact with the inner surface of the female part and to slide therealong before making contact with a preform for producing the pipe insulation, which is preferably a thermal wool material.

Abstract: The inventive process forms a thermoformable preform by pressure laminating a layer of cloth fabric to one face of the thermoplastic substrate, preferably as the substrate is extruded and while still hot from the extrusion process. This fabric/thermoplastic laminated preform can be easily processed in a matched mold press. The fabric should be of a non-stretch type. This non-stretch characteristic, together with its intimate bonding to the thermoplastic substrate, prevents the substrate from thinning in the corner regions. Indeed, because the intimately bonded fabric drags or pulls the substrate from a number of directions as the corner regions are formed, the thermoplastic substrate accumulates and actually thickens in the corner regions, leading to a shell which is remarkably durable and aesthetically pleasing.

Abstract: The semi-finished product according to the invention consists exclusively of liquid crystal thermoplastic polymers (LCP), whereof at least one first liquid crystal thermoplastic polymer (LCP) is in the form of fibers (18) and has a given melting point, and whereof at least one second liquid crystal thermoplastic polymer (LCP) (16) has a melting point below that of the first LCP. This semi-finished product is in particular a fabric. By simply heating under pressure at a temperature equal to the melting point of the second LCP, followed by cooling, a composite material with improved mechanical and physicochemical performance characteristics are obtained.

Abstract: A vulcanizing method including a cylindrical vulcanizing drum for winding and molding unvulcanized rubber belt materials thereover, the vulcanizing drum being removably and rotatably supported on a transfer mechanism. A pair of endless pressurizing bands are arranged to oppose each other with the vulcanizing drum between, the pressurizing bands arcuately surrounding and pressing the corresponding portions of the circumferential surface of the vulcanizing drum. While the circumferential surface of the vulcanizing drum is heated inside, and the respective pressurizing bands are opposingly pressed against the vulcanizing drum, the respective pressurizing bands are synchronously rotated so as to turn the vulcanizing drum and continuously vulcanize the unvulcanized rubber belt molding on the drum.

Abstract: Stampable reinforced thermoplastic sheet, at least one face of which comprises, from the outside to the inside, at least three successive layers abc, in which:a is a matrix comprising a thermoplastic resin reinforced by at least two fillers of different nature and/or type chosen from fillers of the lamellar type and of the spherical or substantially spherical type,b is an interfacial binder chemically compatible with the thermoplastic resin of a and having, with respect to the latter, a lower viscosity at the temperatures at which the sheets are produced and used, andc is a reinforcement comprising a needled glass mat.Articles obtained from the sheets by stamping.

Abstract: A method of forming a textured surface in a sheet of photographic paper by washing the paper for a predetermined period of time, repeatedly cockling the sheet to form a plurality of randomly placed ridges and valleys in the paper, drying the paper, and compressing the paper in a press.

Abstract: A trim board structure which is used for an interior lining, for example, of a ceiling member or a door member of a motor vehicle includes a base member, an inner trim member which is to be exposed, and a cushioning member which is interposed between the base member and the inner trim member. The base member is made of a corrugated cardboard sheet impregnated with resorcinol resin. Due to usage of resorcinol resin, the trim board structure can be molded at a relatively low temperature.

Abstract: A forming assembly comprises two presser members (22,24) each having a corrugated surface for receiving a workpiece made up of generally diamond-shaped pockets (10). Each presser member is made up of sections (22a,22b; 24a, 24b) mounted on slide rods (38) for movement between a spaced-apart position, in which a workpiece can be located therebetween, and a closed position, movement into which, while the workpiece is held between the presser members, is effective to compress the workpiece laterally. For holding the pockets in their diamond shape formers (20) are inserted therein. A flange (18) is formed at one end of the workpiece and integral therewith by pressing outwardly folded material against a lateral end face of the presser members (22,24) using a presser plate (52). This forming method is especially suitable for forming self-supporting filter units.

Abstract: A rigidized fiber filter element is produced from a precursor fiber web. The precursor fiber web contains heat-shrinkable fibers or binder fibers or both. The web is exposed to temperatures sufficiently elevated to cause shrinkage of the fibers or melting of the binder. After cooling the web, the filter elements produced are self-supporting, and may have densities up to 500 kg/m.sup.3 to improve filtration while retaining good functional characteristics for operating pressure drop and air permeability. Rigidized fiber filter elements can be constructed of one material, and thus may be suitable for recycling.

Abstract: A method and apparatus for forming a coreless paper roll having a specifically shaped central aperture. A probe is inserted into the central aperture of the roll after the winding mandrel has been removed from the roll to change the configuration of the central aperture over at least a portion of the length thereof.

Abstract: A method of making blind fabric utilizing natural or synthetic fibers or fabric as base materials to form an inexpensive fabric used in conjunction with conventional venetian and vertical blinds. The method comprises dipping, compressing, tentering, slitting into desired widths, heating, forming and slitting into desired lengths. Whereas the base material is dipped in a mixed solution of (1) thermoplastic resins, (2) thermosetting resins and (3) polyvinyl formal resin, thereafter, compressing said fabric through roller or the like, then tentering it by a tentering machine, slitting it into different widths, heating it at desired temperature to make the fabric soft in order to obtain a non-brittle, relatively flexible fabric. Finally the fabric will be formed into a curved shape and slit into desired lengths to fit the window size. In addition, the fabric can be treated with ultraviolet stabilizer, fire retardant and dust repellent to achieve desired properties.

Abstract: This invention relates to liners containing contaminants, such as styrene, and to methods for lining pipes, such as sewer pipes with liners containing contaminants, such as styrene. In one embodiment, this invention provides a liner and lining method that reduces contamination of the ambient with contaminants from the liner and/or the lining process, such as styrene. In the case of sewers, the carrier pipes lined may be, for example, PVC, clay or concrete, but pipes of metal or other materials, such as asbestos, may also be lined with the liner and lining method of this invention.

Abstract: A rigid self-supporting filter unit is produced by placing two portions of fiber fabric in face-to-face contact and stitching them along parallel regions, using two rows of stitches (16), to form pockets into which formers (20) are inserted to shape the pockets into a generally diamond shape. This assembly is then placed between two presser members (22, 24) which are corrugated, the "valleys" of the corrugations receiving the diamond-shaped formed portions. The presser members are heated and the portions are thus treated by heat and pressure to cause the fabric to be rendered rigid. The formers can then be removed. Suitable fibers for this purpose include a rigidising fiber known as P84, polyphenylene sulphide fibers, polyester fibers either alone or mixed with polypropylene fibers, and bicomponent fibers.

Abstract: A method of molding complex shapes by injecting a plastics material resin into fibers (24, 32) within a mold (10, 34) wherein one or more galleries (22, 40) is provided in the mold communicating with the fibres, the gallery or galleries being so arranged as prevent substantial deformation of the fibres into them. The galleries may be arranged transverse to the length of some or all of the fibres and be sufficiently narrow to prevent deformation of the fibres into them; or the galleries may lie in the same general direction as the length of the fibres and channel inserts (42) provided with a series of transverse slots (44) are employed within the galleries to prevent fibres being pressed into the galleries.

Abstract: Hollow profile elements are formed by shaping a starting workpiece that consists of multiple layers of a material having a large width-to-thickness ratio, e.g., woven fabrics or laid materials. The layers are joined by seams to define elongated pockets or channels. Shaping tools are inserted into these channels to form the profile elements with a desired cross sectional shape, which can be constant or varied. The shaping tools employ one or more endless belts that extend in closed loops around guide rollers; the belts are driven so that during the shaping process sliding friction is substantially eliminated between the material of the workpiece and the respective shaping tool.

Abstract: A method of forming a sheet of material into a flower pot or flower pot cover comprising means for engaging portions of the sheet of material and forming pleats in predetermined portions of the sheet of material having a predetermined shape whereby the formed flower pot or flower pot cover has pleats in predetermined portions and of predetermined shapes.