Abstract: A method for shaping thermoplastic fabrics such as those made of polyester or polyamide fibers into desired three dimensional configurations through a simple procedure. Thermoplastic fabrics are immersed into hot liquid metallic bath made of eutectic metals such as lead, tin, cadmium, zinc and bismuth and formulated to have the eutectic point at least equal to or higher than the softening point of the thermoplastic fibers and lower than the melting point of the fibers. This metallic bath may be called "fluidic lower mold." The thermoplastic fabrics are immersed into the fluidic lower mold by means of an upper mold or core member having desired outer configurations substantially corresponding to those of final products, for example, headrest or seat cushion. The upper mold pushes down the fabric preferably along with a protective sheet laid beneath the fabric into the metallic bath.

Abstract: Accurate and consistent location of jointed textiles within a mold is achieved by inserting the outer surfaces of the joint (12) into the cavity of an elongate, generally U-shaped member (20) and securing the joint to the meter, e.g. by sewing (21). The joint/channel member assembly can then be automatically gripped and placed in the desired position in the mold. The method is of particular application to processes involving vacuum member molding.

Abstract: An apparatus and method is provided for progressively converting each blank of sheet material in a stream of moving blanks into a clamshell assembly having interconnected lid and bottom portions. The apparatus includes a female die assembly having first and second mold cavities, an upstream control system for aligning one portion of each blank at a lid-pressing station defined by the first mold cavity, and a downstream control system for aligning a remaining portion of each blank at a bottom-pressing station defined by the second mold cavity. A male die assembly is provided for simultaneously forming a lid portion in one blank of sheet material and a bottom portion in an adjacent blank of sheet material. In particular, during each pressing cycle, the male die assembly simultaneously presses an initial blank at the bottom-pressing station and a succeeding blank at the lid-pressing station to produce the equivalent of a whole clamshell assembly on a single stroke of the male die assembly.

Abstract: A vacuum (15) as applied to a porous contoured mold (18) for drawing an impervious adhesive film (16) against a cloth fabric layer (14) to conform the cloth fabric layer (14) to the contours of the mold surface. A matching cellular foam cushion pad (12) is placed in mating engagement with the adhesive film (16) as it is held to the contour of the mold surface by the vacuum. The foam pad (12) is compressed against the mold (18) by a perforated platen (36) and held in place as the vacuum is discontinued. Steam is then supplied through the porous mold (12) to heat and diffuse the adhesive film (16) into the adjacent fabric layer (14) and cellular foam pad (12) for adhesively securing the two together. A partial vacuum is then applied for removing moisture by drawing air through the perforations (44) of the platen (36), the foam pad (12), fabric layer (14) and porous mold (18). This ambient air also cools and cures the diffused adhesive between the fabric (14) and the foam (12).

Abstract: A non-woven fabric having a pattern defined by an array of discrete areas having a reduced fibre density but which are substantially free of perforations is produced by supporting a freshly wet laid web of the non-woven fabric on a porous surface and directing spaced jets of fluid against the unsupported side in order to displace fibres within discrete areas while maintaining in position a proportion of fibres that are within those areas and that are adjacent the porous surface. The fabric web may be supported on a Fourdrinier wire (1) and the jets of fluid (e.g. water) may be directed through the apertures in a perforated cylinder (6), the fluid being supplied under pressure from a water-knife device (11). The apertures in the cylinder (6) preferably have a cross-section that increases in the direction of the water jets.

Abstract: This invention relates to methods and apparatus for forming composite material components that have relatively complex surfaces. Currently such components are very expensive to manufacture because forming them requires a good deal of time and hand working of the material. In the system of the invention, a flexible membrane (38) is heated to a forming temperature. Composite material (70) is laid on membrane (38) and heated evenly by contact with membrane (38). Fluid pressure is applied to membrane (38) to force membrane (38) and material (70) upwardly against a mold surface. While it is urged against the mold surface, material (70) flow forms to the shape of the mold surface. Preferably, the mold surface and membrane (38) are rotated about a horizontal axis approximately 180.degree. to position the mold surface below membrane (38) before the fluid pressure is removed to allow membrane (38) to move out of contact with material (70).

Abstract: Reinforced structures of graphite, fiberglass, and the like, together with thermoplastic resinous fibers such as in ribbon, filament and monofilament form are produced. The graphite fiber is combined or blended with a resinous fiber to form a single yarn. The blended yarn is then woven into a soft, supple and flexible fabric having the appropriate concentration of graphite and resin, and with good uniform characteristics. Hybrid fabrics produced by interweaving graphite and the polymeric fibers, ribbon, etc., may be utilized instead of the blended yarn. The fabric is finally shaped to conform with a mold or substrate and heated to melt the resin and produce the resin-graphite laminate.

Abstract: An interwoven fabric having moveable layers of graphite, fiberglass, Kevlar, and similar materials are wrapped or conformed around shaped mold parts. These layered shape parts are subsequently impregnated with resin and cured to produce a reinforced product having a reasonably uniform fiber density. Typical shaped structures include boxes, hemispheres, ojives, etc. The process is particularly suitable for producing structures where the fabric distortion is severe at corners, angles, and so forth.