Abstract: A plurality of joined members each made of thermoplastic resin and having a fluid flow path formed of a groove and/or a hole in a junction face are vacuum-packed in a state in which the joined members are joined to each other. After a wrapped body obtained by the vacuum-packing is heated to soften the joined members, the joined members are welded to each other through the junction faces by applying fluid pressure to an entire outer periphery of the wrapping to evenly pressurize the wrapping from a periphery. Then, the pressurization is cancelled to cool the welded joined members.

Abstract: A process is proposed for the fabrication of parts with large dimensions formed of a skin (10) and stiffeners (12, 16) such as aircraft fuselage segments made of a composite material with a thermoplastic matrix. After stiffeners have been made separately by lay-up, consolidation and shaping, these stiffeners are placed on a tooling (23) and the skin (10) is simultaneously fabricated and assembled to the stiffeners (12, 16) by diffusion welding. More precisely, the skin (10) is laid up and continuously consolidated by the lay-up head (36) such that the required part is obtained directly.

Abstract: A method of manufacturing a composite sheet includes perforating a reinforcement panel. A mold surface onto which the composite sheet may be formed is provided. At least one outer coat of material is applied onto the mold surface. At least one coat of resin and reinforcement material is applied over the outer coat to form a reinforcement layer. The perforated reinforcement panel is applied to the reinforcement layer, and the resin is forced into the perforations formed in the reinforcement panel, thereby bonding the reinforcement layer to the reinforcement panel.

Abstract: A method of producing a composite plastic molded article having at least one layer of web material and a plastic body, includes placement of the web material between mold halves of an injection mold and deforming the web material through closing of the mold. Subsequently, negative pressure is applied on one side of the web material and/or excess pressure is applied on its other side, so that the web material bears upon a mold half. Plastic mass is then introduced into the opening mold in such a way that the feed rate of the plastic mass and the opening speed of the injection mold are coordinated with each other. Once a certain opening gap has been reached, the mold is closed and the plastic article is embossed.

Abstract: A method for forming a tubular object of a composite material involves a first step in which a composite material layer is wound around an iron bar. The iron bar and the composite material layer are then fitted into a contractible plastic covering. The composite material layer is formed into a tubular object in a vacuum chamber into which a thermal medium is introduced. The tubular object is separated from the plastic covering by an air injection between the tubular object and the plastic covering. The iron bar is finally extracted from the tubular object.

Abstract: A unidirectional tape comprising carbon fibers and a fugitive binder is provided, as well as methods for forming the tape and composite parts using the unidirectional tape in a resin-transfer molding (RTM) process. A fugitive binder adheres fibers of the tape. The tape is laid in an RTM mold, and the mold is sealed or vacuum bagged, then heated. Hot nitrogen gas is pumped through the mold cavity, heating the carbon fibers to completely pyrolyze the binder. No residue from the binder remains, as the nitrogen carries gaseous products from the pyrolysis out of the mold. The mold is cooled to a temperature suitable for resin injection, and resin is injected into the mold cavity, wetting the fibers of the tape and completely filling the cavities of the mold. The mold is heated to cause curing of the resin, then cooled and disassembled for removal of the completed composite component.

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

Abstract: A method of resin transfer molding uses an open base mold filled with fiberglass material and a soft tool sealed over the base mold. A vacuum is applied to a vacuum chamber that surrounds the mold and communicates with the fiberglass material through vacuum conduits. Resin is injected into the closed mold and is drawn through the fiberglass material to the edge of the mold with the assistance of the vacuum. The soft tool is preferably a flexible sheet having an edge seal to connect to the base mold and a vacuum channel with a vacuum port that surrounds the mold. The injection head releasably connects to the soft tool and preferably uses a solenoid actuated injector to supply resin to the mold. The injection head can include a self sealing device to seal the injection port and a self cleaning mechanism for flushing resin from the interior chamber of the head.

Abstract: A resin transfer molding (RTM) process is disclosed for rapidly filling a fibrous preform and/or a rigid, porous body with high viscosity resin or pitch. The process is suitable for impregnated multiple porous bodies stacked in a single mold. The process uses a fibrous preform or rigid porous body which is placed into a mold matching the desired part geometry. A resin is injected into the mold at temperature and pressure. After cooling, the infiltrated component is removed from the mold. The mold is constructed from two halves fitted to form at least one mold cavity. A gate fitted with a nozzle is set into one of the mold halves, and a valve admits resin or pitch into the gate area. Venting or vacuum can be applied to the mold. The mold is held in a hydraulic press and an extruder, optionally fitted with an accumulator, supplies molten resin or pitch to the mold.

Abstract: The method of making a tubular member having a continuous and uninterrupted cured elastomeric resin coating on an outer surface of the member includes forming a continuous uninterrupted tubular layer of uncured elastomeric resin and drawing the resin layer against the surface of the tubular member to be coated by applying suction between the resin layer and the surface of the tubular member so that the resin adheres to the surface of the tubular member. The elastomeric resin may then be cured to produce the final product. Apparatus for carrying out the process is disclosed and includes, in sequence, a coating zone including a sub-atmospheric chamber, a heating zone and a feed mechanism for advancing the tubular member relative to the coating and heating zones. A method is also disclosed for molding a distal end cap on an open end of a length of a preformed tubular sleeve member that may be used for prosthetic applications.

Abstract: An automotive quality paint coat (44) is laminated to the exterior surface of a molded plastic car body member or panel (118). In one embodiment, the paint coat (44) includes an exterior clear coat (45) above a color coat (46). During processing, the clear coat (45) and color coat (46) are each coated on a temporary flexible casting sheet (42) and dried. A high gloss surface is transferred to the clear coat (45) from the casting sheet (42). The paint coat (44) is then transferred from the casting sheet (42) to a thin, semi-flexible thermoformable plastic backing sheet (72) by dry paint transfer-laminating techniques. The resulting laminate (70) is thermoformed into a complex three-dimensional shape of the car body member or panel. The preformed laminate (116) is then bonded to an underlying plastic substrate material, by injection-clading techniques, for example, to form the finished article.

Abstract: A three-dimensional spacer fabric resin interlaminar infusion medium and reinforcing composite lamina for use in the vacuum-induced manufacture of fiber reinforced polymer composites is described. This use of the three-dimensional spacer fabric as a composite interlaminar component improves both the vacuum-induced resin infusion flow rate and laminate quality control and aids in the achievement of enhanced resin uniformity distribution throughout the laminate.

Abstract: A process and apparatus for manufacturing fiberglass-reinforced panels are provided. The apparatus includes a guide mechanism and drive mechanism to drive individual elongate molds through a gel coating spraying section and thereafter through an oven to cure the gel coat. The elongate molds are thereafter driven through first and second resin/fiberglass application stations to apply a composite of resin and fiberglass strands. The apparatus also includes a station whereby wooden boards may be placed over the top of the resin and the fiberglass strands, and thereafter to a vacuum station whereby a vacuum can be placed over the wooden boards, such that when a vacuum is drawn on the composite, the resin is drawn into the wooden boards to form an integrated deposit panel.

Abstract: A method is provided for rapidly forming a cementitious panel. A cementitious mixture is introduced into a mold configured to provide the desired surface appearance and profile of the cementitious panel. The cementitious mixture is then subject to an accelerated curing process by applying microwave energy to the cementitious mixture for a predetermined time period. After a relatively short resting or cooling period, the resulting cementitious panel is ready to be removed from the mold.

Abstract: A process for fabricating a face plate for a flat panel display such as a field emission cathode type display is disclosed, the face plate having integral spacer support structures. Also disclosed is a product made by the aforesaid process.

Abstract: A blow molding part with a decorative coating is produced in a three-stage process. The blow molding part is initially produced without a coating in a blow mold tool cavity, and is then molded against the decorative coating material in a second blow-molding operation under low pressure and at a low temperature in a decorative coating cavity. The decorative coating material is heated up if appropriate and is placed in advance against a mold contour. The blow mold tool includes a middle part, which is provided between two movable side parts and can be moved or pivoted out. Mold contours of the middle part form with the mold contours of the side parts the blow mold tool cavity and the decorative coating cavity. The blow mold tool cavity has holding devices for the blow molding part. The decorative coating cavity has suction openings and heating elements for molding the decorative coating material and heating it up.

Abstract: The present invention relates to vacuum forming thermoplastic films by using a porous female mold. The invention further relates to vacuum formed articles, such as automotive interior trim parts made by using the porous female mold.

Abstract: a method for producing a plastic product having a grained surface is disclosed. The method includes heating a sheet shaped laminate material made of a thermoplastic resin to a predetermined temperature, placing the heated laminated material between a male die and a female die. The female die has a grain pattern on an inner surface thereof and a plurality of minute holes therethrough.

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

Abstract: An adjustable mold includes a distortable boundary, a flexible membrane, and a pressurizer, and method of use thereof. Pressure is applied to the flexible membrane, which causes the membrane to distort over the boundary. The shape of the boundary and the distortion of the flexible membrane control the optical characteristics of a lens resulting from the application and curing of a molding composition placed on the flexible membrane or to cast other items having variable shapes determined in part by the flexible membrane. In addition, a mold edge is used to allow casting in predetermined shapes, reducing need for grinding or edging. Visual and emission device calibration features used in conjunction with calibration reference images allow uniform selective distortion of the flexible membrane.

Abstract: Disclosed is a transfer material comprising at least a substrate sheet having releasing property, and a protecting layer formed on one surface of the substrate sheet, wherein the protecting layer is composed of an active energy ray curable resin, the active energy ray curable resin being obtained by heat-crosslinking a heat and active energy ray curable resin composition which comprises, as an active ingredient, a polymer having a (meth)acryl equivalent weight from 100 to 300 g/eq, a hydroxyl value from 20 to 500 and a weight-average molecular weight from 5000 to 50000; a polyfunctional isocyanate; and a UV absorber; characterized in that the UV absorber is a bisbenzotriazole-type UV absorber represented by the formula:  wherein R each independently represents a hydrogen atom, or an alkyl group having 1 to 10 carbon atoms, n each independently represents an integer of 4 to 8, m each independently represents an integer of 1 to 20.

Abstract: A method of producing components with surface decoration, by which even difficult surface geometries can be produced with a satisfactory visible surface, includes prefabricating a sheet-like molding with a desired surface contour in a prior step. The prefabrication is carried out in a contour-defining preforming mold or in a contour-defining production mold. The prefabrication of the sheet-like molding may be carried out, for example, by spraying a material onto a surface of the separate contour-defining mold or of the production mold. The surface decoration may be coated on a rear side with a compact or expanded material and subsequently preformed.

Abstract: A sheet utilized in making electronic displays may be prone to warping. This warping may result in the failure to make good surface-to-surface contact or even electrical connections between layers. By processing the sheet prone to warpage in a flattened configuration, the occurrence of stress-induced cracking when the sheet is applied to a rigid planar structure may be reduced. Moreover, a distorted sheet may be processed economically while still resulting in a final product which is regular, flat and planar.

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

Abstract: A layered arrangement is fabricated by deposit on a mold surface to form a porous foam core of coated microballoons which is assembled within a sandwich between layers of fibrous skin. The sandwich supported on the mold surface is then is sealed within a film enclosure through which a one-shot infusion of liquid resin is performed. After curing and hardening of the infused resin, the film enclosure is removed from the sandwich to expose a multilayered structure.

Abstract: A method of making tooling by preparing a master model having a first surface and casting a thin-skinned mold from a first master surface, with an inner surface corresponding to the first master surface and an outer surface spaced from the inner surface thereof. A bolster is fabricated in releasable contact with the outer surface of the thin-skinned mold and serves as a support structure for the thin-skinned mold or a replica thereof. The bolster and thin-skinned mold are removed from the master and the thin-skinned mold supported by the bolster in contact with the outer surface thereof. A thickness calibration material is located on the inner surface of the thin-skinned mold and corresponds in thickness to an article to be produced. A matching contra halfmold set is formed against the calibration material, the calibration material and thin-skinned mold being supported by the bolster.

Abstract: A manufacturing method for a resin formed element capable of exhibiting an advanced design quality while reducing the manufacturing cost is provided. The method comprises the steps of printing a pattern on a reverse side of a thermoplastic film to form a printed pattern layer, printing and curing an ultraviolet curable or thermosetting resin in part of the surface of the thermoplastic film to form an ultraviolet cured or thermoset resin layer, burying this ultraviolet cured or thermoset resin layer in the thermoplastic film, and forming a resin base material from the printed pattern layer side of the laminated element to adhere and integrate, so as to produce a difference in distance from the surface between the region corresponding to the ultraviolet cured or thermoset resin layer of the printed pattern layer and other region, and finally peeling the ultraviolet cured or thermoset resin layer from the thermoplastic film.

Abstract: A non-woven fabric laminate having stretch properties constructed using hydroentanglement methods is disclosed. The laminate is comprised of at least two layers and utilizes a foam layer as a component in the preferred embodiment, replacing conventional use of fibrous materials. A superior elastomeric fabric utilizing an open or closed cell foam layer as one element of the composite structure and as the elastic member of the fabric results in superior fabric characteristics when compared to similar hydroentangled fabrics which are constructed from fibrous materials.

Abstract: A hybrid injection molding machine that has the capability to draw a decorative or fabric sheet into a mold cavity prior to injection into the mold has opposing male and female mold parts. At least one of the mold parts has an insert formed from a porous metal so that a vacuum may be drawn through the insert in order to draw the fabric sheet into all aspects of the insert cavity so that plastic may then be injection molded into the cavity of the mold.

Abstract: A decorative elastic cushion is manufactured with an elastomer having the physical properties of flexibility and compressibility in a range of flexibilities and compressibilities of stable elastomeric block polymer gels. A film is provided for encapsulating the elastomer and the film includes physical properties of flexibility to enable uninhibited flexure and compression of the elastomer by a user. Decorative printing is disposed on a film interior side facing the elastomer in order to provide photo-like logos and decorations to the cushion, while having a film exterior surface resistant to abrasion and enabling cleaning thereof without affecting the decorative pattern. Printing of the film is effected by heat contacting the film with a printed paper.

Abstract: A process for producing multi-layer game ball products includes the steps of extruding an inner layer precursor as a parison in a partial melt state, forming an outer layer, introducing the inner and outer layers into a mold and expanding the parison within the mold to form the multi-layer game ball product. The outer layer may take the form of pre-cut panels vacuum supported in the mold and an intermediate layer may be provided for dimensional stability in the product. Subsequent to expanding the parison a filler such as foam may be injected into the center space for forming a core.

Abstract: For the continuous manufacture of a twin-wall pipe having a pipe socket and consisting of a smooth internal tube and an external tube, which is welded together therewith and provided with transverse grooves, two extruders are provided, which extrude an external tube and an internal tube via a joint crosshead. Switches are provided for the production of a pipe socket, by means of which the speed of the extruder is modified in such a way that the mass flow of the melt of plastic material for the production of the external tube is reduced during the production of the pipe socket and/or the mass flow for the production of the inner tube is augmented.

Abstract: A method and apparatus for applying labels to cylindrical portions of plastic bottles by in-mold labeling utilizes an indexing label magazine which dispenses labels to first label engaging heads and, following indexing of said label magazine, dispenses labels to second label engaging heads.

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: Apparatus for manufacturing a molded article having a substrate material and skin material may include a first die that receives and supports the substrate material and a second die that receives and supports the skin material. The first die is arranged and constructed to engage the first die. A cutter may be provided on the first molding die. The cutter can be actuated when the second die moves toward the first die in order to partially cut away the substrate material.

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 granular, ground filler of plant origin, such as kenaf fiber, is mixed into a synthetic resin to form a melted synthetic resin Ca, which is extruded from an output port 36 of a low-pressure extruder 30 as an intermediate resin layer C. A first coating material A and a second coating material B are superimposed on the two surfaces of the intermediate resin layer C. Thereafter, both coating materials A and B are pressed and adhered to the melted intermediate resin layer C by a roller press 50.

Abstract: The present invention relates to methods and apparatus of molding composite parts by liquid resin infusion. The invention involves the creation of temporary resin distribution channels on the surface of a preform to aid in the distribution of resin during infiltration. In general, these methods are improvements over the art because the molds are cheaper to make, the parts produced are of higher quality, minimal waste is produced and the time to infiltrate the preform is reduced.

Abstract: A composite material includes five distinct layers of material: two thin outer layers or panels, a central rigid core and intermediate foam layers on both sides of the core which fill the regions between the core and outer panels. The core can be a wide variety of material but is preferably a rigid foam or wood having resin or epoxy impregnated fiber or fiber filled outer skins. An array of apertures extends through the core. During the fabrication process, the apertures facilitate cross flow of the foam and ensure even distribution thereof. As a finished product, the foam filled apertures ensure positive location and retention of the core within the foam. The foam may be any suitable injectable foam but is preferably a composition which remains resilient upon curing as such foam more readily accommodates dimensional changes between the layers due to, for example, ambient temperatures changes.

Abstract: A method and system for casting a thermoset layer over a golf ball precursor product is disclosed herein. The system includes multiple stations connected by a conveyor system. The thermoset flowable material is dispensed into a plurality of cavities on each of the mold halves. A plurality of golf ball precursor products are then centered and inserted into the first mold half cavities. The mold halves are mated, heated and cooled. Then, at a de-molding station, the mold halves are separated and the thermoset layered golf balls are removed from the second mold half. A preferred thermoset material is a thermoset polyurethane.

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 novel fiber-reinforced composite member having at least one projection is formed by (a) disposing a preform made of a fiber-reinforced composite material on a forming plate; (b) placing a shape-retention means composed of a plurality of soft unit members adjacent to each projection of the preform; (c) completely covering the preform and the shape-retention means with a bagging film having a sealant attached to the periphery; (d) adhering the sealant to the forming plate such that the preform and the shape-retention means are completely sealed by the bagging film; (e) evacuating the inside of the bagging film; and (f) heating the preform under pressure to form a fiber-reinforced composite member.

Abstract: A method and system for inserting a golf ball precursor product into a cavity of a mold half for precision centering is disclosed herein. The precision centering allows for the concentricity of core in relation to the cover of a golf ball. The system includes an insertion mechanism that allows for the vertical movement of a plurality of vacuum cups along a longitudinal pathway. The vacuum cups retain the golf ball precursor products and insert each into a corresponding cavity on a mold half. As the vacuum cups are lowered along the longitudinal pathway, the mold half is elevated along the longitudinal pathway. The mold half and vacuum cups meet at an insertion position where the golf ball precursor products are released from the vacuum cups and set within a thermoset material contained in each of the cavities.

Abstract: A process for reconstituting or reconstructing a composite object having a defect which affects at least its surface includes: (a) placing at least one added piece or material, the shape and dimensions of which are matched to those of the defect, in or on the defect, the piece or material including mechanically strong, continuous or staple fibers; (b) placing a polymer material in or on the defect to obtain a plastic matrix in which the fibers are distributed; (c) placing a gas-drain for draining the gases given off by the plastic matrix and a cover for extracting the gases, in succession and one on top of the other, on the added piece, which together with the rest of the object form an enclosure which is sealed with respect to the external atmosphere and circumscribes the defect and the added piece; and (d) while evacuating the sealed enclosure, heating the added piece using a radiant source, the emission from which includes infrared radiation, and placing the source with respect to the defect so as to irrad

Abstract: A composite molded article of light weight and low cost, and producing method thereof, and also, an inner mold and a metal mold which are used for producing a cellular molded article in mold pattern having surface skin and capable to be preheated even in a condition of opening the metal mold so that the molding cycle can be shortened.

Abstract: A method and apparatus for producing tubular molded products from molding material includes a mold casing and a mold core having a common longitudinal central axis which is vertically disposed. The mold casing and mold core are spaced from one another to define a molding space therebetween. A supply device supplies molding material from above the molding space into the molding space. Treatment apparatus is disposed at treatment zones on the mold core for treating the molding material in the molding space, the treatment including treating the molding material by shaking the molding material or treating the molding material by heating the molding material, or both.

Abstract: There are disclosed:

Abstract: An instrument panel is provided having a skin material integrally bonded to the surface of a thermoplastic resin core material. The panel is obtained by feeding the skin material to a cavity between a pair of male and female molds having been designed so as to give a desired instrument panel shape, and press-molding a molten thermoplastic resin after or while feeding the molten thermoplastic resin to the cavity between the skin material and the male mold or the female mold. Brackets are formed integrally, by press-molding, with the core material resin on opposing end portions and at a back portion of the instrument panel.

Abstract: A method of depositing a thin membrane so that it conforms to an irregular shaped surface of a scintillator includes the steps of aligning the membrane in a desired position with respect to the irregular surface so that the membrane is in contact with at least some protruding portions of the scintillator, and drawing the membrane down over the irregular surface so that the membrane is conformingly disposed around substantially all protrusions without deforming or bending the needle-like protrusions. The membrane is drawn down by applying a substantially uniform differential pressure across the thin membrane so as to urge the membrane into conformal contact with irregular surface. An imager array fabricated with this process includes a scintillator having an irregular surface and a monolithic reflective layer disposed thereover in conformal contact with the irregular surface.

Abstract: In order to reduce the throughput times of a manufacturing process and the space required for the manufacturing facilities for a plastic injection molding that is laminated with a textile fabric, a non-woven or the like, particularly a piece of interior trim for an automobile, a process is provided comprising the following steps: loading of a fabric blank, which is coated on a first side facing the injection molding with a plastic film that is thermoformable and, when cooled, dimensionally stable and elastic; preforming the fabric blank into the desired outer contour of the injection molding to be manufactured; inserting the preformed fabric blank into the injection mold; injection-backing the fabric blank with plastic; and ejecting the laminated injection molding.