Abstract: A composite structure is made by placing a stiffener preform and a composite structure reinforcement on a tool. The preform and the reinforcement are vacuum bagged processed and co-infused with a thermoset resin to form a stiffened, unitized structure.

Abstract: The presently disclosed and claimed inventive concept(s) relates to a transparent and reusable vacuum infusion heating bag for heating one or more curable materials against a tool, dispersing a permeating substance through the curable material and forming composite parts. The transparent and reusable vacuum infusion heating bag comprises a substantially transparent laminate containing a heating element. The heating element is sandwiched between a first layer and a second layer of flexible polymer material.

Abstract: A substrate sealing apparatus includes a chamber, at least one lower compressing member, and at least one lower compressing member. The lower compressing member includes a lower compressing surface for emitting heat, is configured to be elevated up and lowered down in a vertical direction with respect to the compressing surface, and rotates about the vertical direction. The upper compressing member includes a lower compressing surface for emitting heat, and is configured to be elevated up and lowered down in the vertical direction.

Abstract: A caul plate system for a laminate structure includes a plurality of layers of curable caul plies disposed over a laminate structure and substantially conforming to a surface of the laminate structure. A resin is applied to the plurality of layers of caul plies. Co-curing of the plurality of layers of caul plies with the laminate structure hardens the plurality of layers of caul plies such that a normal pressure is applied to the laminate structure during cure of the laminate structure.

Abstract: A polyetheretherketone pipe of length greater than 250 meters and a residual stress of less than 5 MPa may be made using a calibrator device (2) which includes a cone shaped opening (6) arranged to receive a molten extruded pipe shaped polymer. Attached to the front member (4) is a vacuum plate (14a) and successive vacuum plates (14b-14h) are attached to one another to define an array of vacuum plates, the vacuum plates being arranged to allow a vacuum to be applied to a pipe precursor passing through opening (16). The vacuum plates (14) also include (10) temperature control means for heating or cooling the plates and therefore heating or cooling a pipe precursor passing through the openings.

Abstract: A method of manufacturing a golf ball includes molding a cover preform in a first mold. The cover preform is placed in a second mold. Material is injected into an interior of the cover preform. The material forces the cover preform against a surface of the second mold to form dimples in the cover. The dimples may extend through the cover to form dimple structures in at least one layer between the cover and a center of the golf ball. For instance, the dimples may extend through the cover and into the injected material. The dimples may have a depth greater than a thickness of the cover.

Abstract: A fabrication process using an integrated form includes assembling at least two independent sections of composite laminate about a form, such that at least a portion of the sections overlap. A bonding agent is applied between the sections, at the overlap, and the form and laminate assembly are vacuum-bagged. The bag is sealed around a vent in the form, and about the laminate assembly. A vacuum is applied within the bag, to bond the sections, and the bagged assembly is autoclaved, to cure the bonded laminate sections. The vent allows equalization of autoclave pressures within and outside of the form, to prevent crushing or deformation of the form during cure. The form becomes an integral and permanent part of the final composite product.

Abstract: A process for manufacturing a composite block of closed geometry, in the form of a continuous ring, based on fibers and on a crosslinkable resin, by continuous winding and superposition of several layers of a tape of reinforcement fibers embedded in a matrix based on a composition comprising a crosslinkable resin. The process comprises from upstream to downstream, the following steps: producing a rectilinear arrangement (12) of reinforcement fibers (11) and conveying this arrangement in a feed direction (F); degassing the arrangement (12) of fibers by the action of a vacuum (13); after degassing, impregnating said arrangement (12) of fibers under vacuum with said resin composition in the liquid state (17); passing the pre-preg thus obtained through a die (20) to make said pre-preg into the form of a tape (21) composed of reinforcement fibers (11) in their liquid resin (17) matrix, the thickness of said tape being less than 0.

Abstract: The invention relates to a method for joining precured stringers to at least one structural component of an aircraft or spacecraft. A vacuum arrangement required for the joining is produced in two parts. In a first step, each precured stringer is covered in advance by a covering vacuum film. The stringers prepared in this manner are arranged on the structural component. Vacuum film strips are subsequently arranged in each case on adjacent stringers and over an intermediate space between the adjacent stringers. With the use of a vacuum sealing means, the vacuum film strips and the covering vacuum films 8 form a continuous vacuum arrangement. The stringers are subsequently joined under pressurization to the structural component with the use of this vacuum arrangement.

Abstract: A method and system is provided for forming a three-dimensional image and, more particularly, for making three-dimensional digital image transfer thermoformed objects on, e.g., generic molds. The method includes manipulating digital images of a subject into a single image; printing the single image onto a media; and thermoforming the media with the single image using a generic mold. The system comprises a computer infrastructure operable to: receive images of a subject; display the images; stitch together the images to form a single image; adjust portions of the images or single image to compensate for deformation during thermoforming of the single image; register the single image with points on a mold; and print the single image.

Abstract: The present invention provides apparatus and methods for growing fullerene nanotube forests, and forming nanotube films, threads and composite structures therefrom. In some embodiments, an interior-flow substrate includes a porous surface and one or more interior passages that provide reactant gas to an interior portion of a densely packed nanotube forest as it is growing. In some embodiments, a continuous-growth furnace is provided that includes an access port for removing nanotube forests without cooling the furnace substantially. In other embodiments, a nanotube film can be pulled from the nanotube forest without removing the forest from the furnace. A nanotube film loom is described. An apparatus for building layers of nanotube films on a continuous web is described.

Abstract: A method of manufacturing a component by molding is provided. A mold has a mold surface representing a negative image of the component. The mold has openings in the mold surface. Flow channels extending from the openings in the mold surface and are connectable to a suction device. Further, the mold has a periphery delimiting the mold surface. A bag is fixed to the periphery of the mold. The bag is inflated to a pressure level above ambient pressure. The pressure is released from the bag while sucking the bag to the mold surface using the suction device. Fabrics are layered onto the bag while the bag is kept sucked to the mold surface. Resin is introduced into the fabrics and then the resin is cured.

Abstract: The present invention relates to sheet-form fibre composite components which are obtainable by impregnating fibres with a reactive resin mixture comprising polyisocyanates, polyepoxides, polyols and optionally additives, and to a process for the production thereof.

Abstract: The present invention relates to a decorated injection molded article having an embossed pattern comprising a surface layer comprising an acryl resin film, a printing layer provided on an inside of the surface layer, an adhesive layer provided on an inside of the printing layer and an injected resin layer, wherein a concavo-convex pattern is provided on the surface of the surface layer at a front face part and a side face part of the injection molded article by emboss processing and further to a method for producing the same, and the present invention provides a decorated injection molded article having an embossed pattern, in which a concavo-convex pattern is easily formed on the surface and which is imparted with a steric design property having a higher grade feeling.

Abstract: A hollow plastic body comprises a material composite consisting of a stamp-formed panel or sheet-like first layer of a first thermoplastic synthetic material, an optionally stamp-formed panel or sheet-like second layer of a second synthetic material, and an open-cell or mixed-cell foam layer of a third synthetic material disposed between the first and the second layer. The foam layer may be compressed at least in some sections in accordance with the stamped form of the first layer and/or the second layer. The foam layer may be in mechanical contact with the first or/and second layer substantially only in the compressed sections. Advantageous manufacturing methods for hollow plastic bodies are further disclosed.

Abstract: A method of RTM molding including placing a reinforcing fiber substrate in a mold, placing a resin distribution medium having a resin flow resistance lower than a resin flow resistance of said reinforcing fiber substrate on a surface of said reinforcing fiber substrate opposite said mold, providing a degasification medium comprising a gas permeation film and a gas permeable substrate between said reinforcing fiber substrate and said mold, and injecting a resin into said mold through said resin distribution medium after pressure in said mold is reduced by evacuation, whereby the injected resin is impregnated into said reinforcing fiber substrate by evacuating said resin injected from a degasification space formed between said gas permeation film and said mold.

Abstract: A method of RTM molding includes placing a reinforcing fiber substrate in a mold, placing resin distribution media exhibiting a resin flow resistance lower than a resin flow resistance of said reinforcing fiber substrate on both surfaces of said reinforcing fiber substrate, and after pressure in said mold is reduced by evacuation, injecting a resin into said mold through said resin distribution media to impregnate said reinforcing fiber substrate with said resin injected, wherein resin flow resistance of a first resin distribution medium placed on a first surface of said reinforcing fiber substrate is lower than resin flow resistance of a second resin distribution medium placed on a second surface of said reinforcing fiber substrate, and said evacuation is carried out through said second resin distribution medium while said resin is injected into said first resin distribution medium to impregnate said reinforcing fiber substrate with said resin injected.

Abstract: A new cladding panel for use on recreational vehicles is produced by either a hand-laid or vacuum infusion process. In the hand-laid method, the cladding is formed by first introducing and curing a layer of gel coat onto a mold surface. Layers of fiber reinforced resin material are subsequently laid onto the gel coating and molded to form the cladding panel. In the vacuum infusion process, the gel coating is first laid onto a mold surface of a vacuum infusion mold, and then dry ply materials are laid onto the gel coating. The mold is closed and a resin component is infused into the dry laminate material under vacuum pressure and cured. The cladding panels produced by these methods produced are seamless and have limited waste associated with post-production trimming processes. Cladding panels produced using the vacuum infusion process have a more consistent composition and achieve improved part-to-part consistency.

Abstract: A holding tool 2 for use in producing of laminated glass includes a frame 3, a bag member 4 and a supporting member 6b for suspending the bag member 4 from the frame 3. The bag member 4 is made of a film with flexibility and airtightness, is provided with a sealable opening and has evacuating ports 7a and 7b in the vicinity of an periphery of a flat shape thereof having the periphery sealed. The frame 3 has a first frame member 3w and a second frame member 3y opposing each other and disposed outside the periphery of the bag member 4, and the bag member 4 is suspended by the supporting member 6b movably against the frame 3 on a holding face formed at least by the first frame member 3w and the second frame member 3y inside an area formed by connecting ends of these frame members.

Abstract: A method and part forming apparatus configured for forming an aircraft stringer. The part forming apparatus may comprise a forming tool, a rigid plate, and a hollow bladder. The forming tool may comprise a material trough, a bladder extension trough laterally aligned with and open to the material trough, and a recessed pocket extending from either side of the bladder extension trough and adjacent to the material trough. The method comprises placing composite material into the material trough, placing the bladder onto the composite material and through the bladder extension trough, placing the rigid plate into the recessed pocket and over the bladder, and then placing skin laminate over the bladder and the composite material. Once each of these components is in place, the forming tool may be vacuum bagged and the composite material and skin laminate may be co-cured to form the stringer.

Abstract: A method for producing a foamed article including a supporting element, a foam layer, and an upholstery cover applied on said foam layer, comprising the steps of forming said upholstery cover by stitching together a plurality of lengths of upholstery cover, positioning the sewn upholstery cover on a convex positioning surface of a positioning member withholding the sewn upholstery cover on said positioning member by means of a first suction system, setting said positioning member with the sewn upholstery cover withheld thereon by suction in a bottom die of a foaming die, deactivating said first suction system and withholding the upholstery cover on a concave positioning surface of said bottom die by means of a second suction system, extracting said positioning member from said bottom die leaving said upholstery cover positioned and withheld by suction on said concave positioning surface, positioning a rigid supporting element on a plunger of said foaming die and closing the plunger on said bottom die so as to

Abstract: A method is provided for molding a composite part defined by using a preform comprising a shape memory polymer (SMP) binder. A bound preform comprising the SMP binder in a permanent shape and defined by a simplified geometry provided to a mold. The bound preform is heated above a transformation temperature of the SMP binder and deformed into a shaped preform defined by the temporary shape of the SMP binder. In a molding sequence, the shaped preform is constrained in its temporary shape by the mold while resin is introduced to the mold and cured to produce a final part. The shape of the cured part defines the temporary shape of the SMP binder. The bound preform may be generally configured as a mat or be defined by a substantially flat surface such that the preform may be used as a preform to mold a variety of differing part configurations.

Abstract: A use of a core block for an impregnation process as well as a composite structure comprising such a core block is described. The core block has a first surface and a second surface, and a number of first grooves is formed in the first surface of the core. Furthermore, a number of second grooves is formed in the second surface of the core. The first grooves have a first height (h1) and a bottom, and the first grooves and the second grooves are part of a resin distribution network formed in the core block. The distance (t) between the bottom of the first grooves and the second surface of the core block is of such a size that the core block is flexible along the first grooves. Additionally, the sum of the first height and the second height is larger than the thickness of the core block, and at least one of the first grooves in the first surface of the core block crosses at least one of the second grooves in the second surface of the core block.

Abstract: A breather for vacuum bag processing of a part comprises a sleeve of resilient material placed around the part.

Abstract: An industrial-scale high throughput wafer bonding apparatus includes a wafer bonder chamber extending along a main axis and comprising a plurality of chamber zones, a plurality of heater/isolator plates, a guide rod system extending along the main axis, a pair of parallel track rods extending along the main axis, and first pressure means. The chamber zones are separated from each other and thermally isolated from each other by the heater/isolator plates. The heater/isolator plates are oriented perpendicular to the main axis, are movably supported and guided by the guide rod system and are configured to move along the direction of the main axis. Each of the chamber zones is dimensioned to accommodate an aligned wafer pair and the wafer pairs are configured to be supported by the parallel track rods. The first pressure means is configured to apply a first force perpendicular to a first end heater/isolator plate.

Abstract: A method of RTM molding wherein a reinforcing fiber substrate is placed in a mold, each of a first and a second resin distribution media exhibiting a resin flow resistance lower than the resistance of the reinforcing fiber substrate is placed on each surface of the reinforcing fiber substrate, and the inside of the mold is evacuated and a resin is injected into the mold to thereby impregnate the reinforcing fiber substrate with the resin injected, characterized in that the first resin distribution medium exhibits a resin flow resistance lower than that of the second resin distribution medium, and the evacuation is carried out through the second resin distribution medium while the resin is injected through the first resin distribution medium. The method can be advantageously employed for producing, in particular, FRP structure which is thick and excellent in designability, lightweight property and/or strength.

Abstract: Composite sections for aircraft fuselages and other structures, and methods and systems for manufacturing such sections, are disclosed herein. A method for manufacturing a shell structure in accordance with one embodiment of the invention includes applying composite material to an interior mold surface of a tool to form a skin extending 360 degrees around an axis. The method can further include positioning a plurality of stiffeners on an inner surface of the skin. After the stiffeners have been positioned, a vacuum bag can be installed over the stiffeners and evacuated to press the stiffeners and the skin outwardly against the interior mold surface of the tool. Next, the skin/stiffener combination can be cocured to bond the stiffeners to the skin and harden the shell structure.

Abstract: A biodegradable polymer stent with radiopacity and a method of making and using a stent with enhanced mechanical strength and/or controlled degradation for use in a bodily lumen is described.

Abstract: A multi-segment tool and tooling system for vacuum forming a composite part. A tool can include a first tool having first and second surfaces. A second tool can have an opening positioned on a first tool in a location other than the first surface or the second surface. The first tool and second tool can receive at least a portion of a preform composite. The first tool can have a vacuum barrier attached to the first surface and to the second surface encapsulating the preform composite and the second tool. A tooling system can include a first tool having a core and a base with a core extending upwards from the base. A second tool can be positioned upon the core where the core extends above the second tool. A vacuum barrier sealed to the base and the core can include a composite, the first tool and the second tool.

Abstract: A component is produced according to the following steps: a) insertion at least of two skins into the second tool half of a tool having a cavity-forming first tool half and second tool half such that the skins overlap in their end regions; b) rear-foaming or rear-spraying of the skins with a foam material or spraying material, c) by exerting low pressure in the region of the overlap, the internally situated end region of the one skin being pressed against the externally situated end region of the other skin in a foam-tight or injection molding-tight manner.

Abstract: A method of manufacturing a fiber-reinforced article. The method includes the steps of providing a mat fiber structure defining voids therein. A membrane structure is applied over at least a portion of the fiber structure. The membrane structure includes a microporous membrane. At least the microporous membrane of the membrane structure has an oil resistance rating of at least a number 8 determined by AATCC 118 testing. A resin and hardener mix is provided. The resin is infused into voids of the fiber structure by applying a vacuum to the fiber structure and the membrane structure wherein the membrane structure inhibits the flow of resin therethrough.

Abstract: A stiffened skin panel of an aircraft that includes an aircraft skin panel of composite material and a composite stringer consolidated with the aircraft skin panel. The stringer has a pair of stringer sides, each extending from a stringer top to a stringer leg. The stringer sides may each extend through a wide radius, smooth continuous curve to a stringer leg. The wide radius, smooth continuous curve may be proximate the base of the stringer side in a region where the stringer side transitions to the stringer leg.

Abstract: A method for producing a container associable with airless pumps, in the interior of which container a deformable bag is formed by blow molding a preform of plastic material. A vacuum is created in the container interior during or slightly before blowing.

Abstract: A method of manufacturing an article includes simultaneously holding, with a vacuum device, a first object and a second object that are overlapped and abutted against each other. The method also includes simultaneously transporting the first and second objects relative to a machine. Still further, the method includes attaching the first and second objects together with the machine.

Abstract: A method of decorating a molded article is provided that includes the steps of: (a) providing a mold insert comprising a plurality of flock fibers and a permanent adhesive layer; (b) positioning the mold insert in a mold; and (c) introducing resin into the mold, such that a resin contacts the mold insert to form a molded article. The melting point of the permanent adhesive layer is preferably greater than a temperature of the resin during molding.

Abstract: A curved composite aircraft frame comprises a multi-ply composite laminate having a generally Z-shaped cross section. At least certain of the laminate plies include unidirectional reinforcing fibers that are substantially tangent at substantially all points along the curvature of the frame.

Abstract: A vehicle deck board 1 is molded in such a manner that a lower die 21 and an upper die 22 are clamped together in a state where foamed resins 13 and reinforcements 20 are interposed between a back surface side sheet material 16 and a front surface side sheet material 15, whereby the back surface side sheet material 16 and the front surface side sheet material 15 are welded to each other to thereby form a laminated member 26 with height-increasing bridge members included therein, compressed air is injected into an inside of the laminated member 26 with the height-increasing bridge members included therein, which is formed by welding the back surface side sheet material 16 and the front surface side sheet 15, while individually vacuum-sucking the back surface side sheet material 16 and the front surface side sheet material 15 to the lower die 21 and the upper die 22, and the laminated member 26 concerned is subjected to blow molding.

Abstract: A flexible compaction sheet is used to compact uncured composite plies onto the surface of a ply layup. The compaction sheet includes a peripheral seal that seals the perimeter of the sheet to the surface of the part layup and forms a vacuum chamber over the plies which is evacuated through the sheet to apply compaction pressure to the plies.

Abstract: A method of manufacturing root of megawatt wind-turbine blade includes the following steps: (1) manufacturing an independent female mould, and arranging a positioning stop-ring on the female mould; (2) clinging on one side of the positioning stop-ring, a plurality of glass fabrics and macroporous glass fabrics are laid on the curved surface of the female mould; (3) after laying the glass fabrics, sealing the female mould using a vacuum bag, and vacuumizing the female mould after a curved supporting board is arranged on the vacuum bag; (4) after laying a plurality of glass fabrics in the blade mould, slinging the prefabricated part and the curved supporting board to arrange them in the blade mould; (5) sealing the blade mould using another vacuum bag, vacuumizing the blade mould, thereafter infusing resin into the blade mould, after curing the root of the blade is finally formed.

Abstract: A micro-lens array fabrication apparatus includes a first roller, a second roller, a molding member, and a cooling member. The first roller and the second roller revolve cooperatively to position portions of a substrate on the molding member while maintaining a tension on the substrate. The molding member includes a shaft and two caps connected to opposites ends of the shaft. The shaft defines a through hole and rows of molding holes in a lateral surface thereof, and forms heaters in the though hole. The heaters heat up the substrate till molten, and the air is driven to blow the molten substrate into the molding holes and form a row of micro-lens structures on the currently positioned portion of the substrate.

Abstract: A method of making a tool for curing a composite layup and a method of removing air and volatiles from a composite layup during curing. The tool includes a tool body having a surface adapted to support a composite layup and includes an integrated breather for allowing removal of air from the layup during curing.

Abstract: The present invention aims to provide a manufacturing method for a PDP which allows even high-definition and ultra-high-definition PDPs to demonstrate an excellent image display capability at improved luminous efficiency, by suppressing variation of a discharge gas composition, and by eliminating an impurity gas in a discharge space effectively. To achieve the aim, deterioration of an absorbent material 39 composed of copper ion-exchanged ZSM-5-type zeolite is prevented, by performing both sealing and evacuation steps for the front substrate 2 and back substrate 9 in a non-oxidizing gas atmosphere. This maintains properties of the absorbent material 39 for absorbing the impurity gas without degradation, even if the absorbent material 39 absorbs a Xe gas in a discharge gas introducing step.

Abstract: A method in which a fibre material is laid on a mould surface resembling a negative image of a fibre reinforced structure to be produced. Layering the fibre material on the mould surface includes laying rovings of the fibre material on the mould surface or on a fibre material already laid on the mould surface and applying an low pressure to a space between the rovings and the mould surface.

Abstract: A holding tool 2 for use in producing of laminated glass includes a frame 3, a bag member 4 and a supporting member 6b for suspending the bag member 4 from the frame 3. The bag member 4 is made of a film with flexibility and airtightness, is provided with a sealable opening and has evacuating ports 7a and 7b in the vicinity of an periphery of a flat shape thereof having the periphery sealed. The frame 3 has a first frame member 3w and a second frame member 3y opposing each other and disposed outside the periphery of the bag member 4, and the bag member 4 is suspended by the supporting member 6b movably against the frame 3 on a holding face formed at least by the first frame member 3w and the second frame member 3y inside an area formed by connecting ends of these frame members.

Abstract: A method of producing a composite shell structure in the form of a wind turbine blade shell part having a reinforced fibre material embedded in a cured resin includes: providing a mould part having a contour defining the outer surface of the composite shell structure; providing a preform forming part shaped complementary to the mould part moulding surface; forming a preform of dry fibre material on the surface of the preform forming part; arranging the mould part and the preform forming part in an assembled position with the mould part moulding surface facing the preform forming surface; releasing the preform from the preform forming surface so that it is received on the mould part moulding surface; removing the preform forming part from the mould part; forming a mould cavity by means of a second mould part arranged on the preform; providing resin in the mould cavity; and curing the resin.

Abstract: A method for manufacturing a composite is provided. A first fibre mat is laid onto an inner surface of a mould. Suction is applied between the inner surface of the mould and the first fibre mat. A second fibre mat is laid over the first fibre mat, wherein the second fibre mat is covered with a vacuum bag. Vacuum is introduced between the vacuum bag and the mould and resin is injected under vacuum between the vacuum bag and the mould. After the resin is set, the mould will be removed.

Abstract: Process for manufacturing a fuel tank equipped with an internal accessory and having a plastic wall produced from a parison, said process comprising, in order, the following steps: a) the accessory and the molten parison are introduced into a mould so that the accessory is surrounded by the parison, said mould comprising cavities equipped with at least one moving part; b) a pressurized gas is introduced inside the parison to carry out a pre-blow moulding of said parison; c) the pre-blow-moulded parison is pressed locally against the accessory using the moving part in order to firmly attach the two without piercing the parison; d) the mould is closed and the final blow moulding of the parison is carried out by flattening it against the mould cavities using the pressurized gas; and e) the tank is removed from the mould.

Abstract: The present invention is directed towards a system for expelling a gas positioned between a substrate and a mold, the substrate and the mold further having a liquid positioned therebetween.

Abstract: A mold includes a forming insert that includes an upper portion and a lower portion. The upper portion includes a sidewall segment and a heel segment extending from a bottom of the sidewall segment. The sidewall segment has a sidewall radius, and the heel segment has a heel radius that is less than the sidewall radius. The lower portion extends axially downward from the upper portion to define a base cavity. A forming base is positionable within the base cavity. The rim has a rim radius that is less than the heel radius and the step has a step radius that is less than the rim radius.

Abstract: Methods and apparatus for fabricating adhesive bonded joints while minimizing the voids and/or porosity found in the cured bondline. In accordance with various embodiments, the apparatus comprises an evacuation chamber combined with a pressure inducing device to produce bonded joints that are both void free and thoroughly compacted. The surfaces to be bonded are continuously evacuated throughout the bonding process (pre-mating, mating, debulking and cure). Continuous evacuation is provided via standard vacuum, while the induced pressure can be pneumatically or mechanically provided.