Abstract: A molding system and methods of forming a structure are presented. The molding system is configured to sequentially form features of a structure. The molding system comprises a first tool comprising a number of features configured to completely form a first set of radii of a structure and a number of partial forming features configured to partially form a second set of radii of the structure, and a second tool comprising a number of completion features configured to complete shaping of the second set of radii.

Abstract: Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.

Abstract: A heat brake for heating and softening a thermoplastic sheet for bending is disclosed. The heat brake has a split work piece support table having two edges defining a slot between adjacent portions of the table. A first plenum is provided below the split work support table. During operation, the first plenum has a negative pressure. Air is drawn into the first plenum through the slot when a work piece does not span the slot. When a work piece spans the slot, the flow of air into the first plenum is reduced. The heat brake has a tube heater with an outlet nozzle positioned in the first plenum. A portion of the tube heater is positioned in a second plenum which is pressurized during heating. Air is moved from the second plenum through the heater tube and is directed against a work piece supported on the table.

Abstract: A method and an article of manufacture are disclosed for making a load bearing structural container with a reinforced wrap, substantially without using additional structural reinforcements. In various embodiments, a fiber reinforced polymer sheet may be used as the reinforced wrap to make the reinforced wrap container having detailed patterns and complex shapes embedded therein using a molding technique. Once the wrap is set and cured, the container holds its shape permanently. The container may include burial caskets and coffins, various shaped boxes, and cases for musical instrument, jewelry technical or medical equipment, guns, camera equipment, and the like. The Container may also be used as shipping packaging for the same types of equipment enumerated above.

Abstract: A process for making a reservoir including steps of positioning a hollow extrudate at an elevated temperature in a mold cavity, inserting a fitting into an end of the extrudate, sealing an outer surface of the fitting with an interior surface of the extrudate using latent heat within the extrudate, and forming at least a portion of the extrudate against the mold cavity forming a reservoir with the fitting sealed into the reservoir.

Abstract: The present disclosure provides a method of forming a flame retarded composite article using a halogen-free thermosetting composition comprising a benzoxazine compound, a monobenzoxazine monomer, and a naphthalene epoxy. The flame retarded composite article formed is especially suited for use in aerospace, automobile, rail and marine applications.

Abstract: Techniques and apparatus for providing a flexible shape low volume autoclave are disclosed. In one embodiment, an autoclave includes an elongated pressure vessel that is sealed on both ends and has a circumferential joint between a first portion and a second portion. The autoclave further includes the portions defining an interior configured for accepting an elongated part, the joint being configured to create an angle between the portions and further creating an opening with a seal, the opening facilitating an insertion of the part into the interior, and the seal enabling pressurization of the interior.

Abstract: A method of attaching a composite member to a structure. The method including forming a laminate of fabric impregnated with resin; applying heat at a first temperature to the impregnated laminate; applying vacuum at a first pressure to the impregnated laminate to degas the resin and form a degassed, impregnated laminate; positioning the degassed, impregnated laminate on a structure; and curing the degassed, impregnated laminate on the substrate by applying heat at a second temperature and by applying vacuum at a second pressure.

Abstract: The present invention generally relates to a mold assembly (32, 34) and a method of using the mold for the manufacture of composite parts which, more particularly, are generated from a strengthener in a generally solid phase and a matrix in a generally liquid phase. Various types of molds and processes may be used in order to impregnate a strengthener with a matrix such that a composite part may be manufactured, but the efficiency rate and the duration of the manufacturing process significantly varies depending on the chosen type of mold and process. The present invention relates to a mold assembly and to the manufacture of composites by using the mold assembly which includes the injection of the matrix in the mold assembly containing the strengthener and a deformable member (36) which favors the impregnation of the matrix toward the strengthener.

Abstract: A process for producing a fiber reinforced resin which comprises placing at least a reinforcing fiber substrate in a cavity of a mold, injecting a resin into the cavity, and curing the resin, characterized in that a substrate for forming a skin layer, and a resin distribution medium, which is located between the substrate for forming the skin layer and the reinforcing fiber substrate and in which the ratio of the coefficient of impregnation thereof to that of the substrate for forming the skin layer is 1.5-10, are disposed on at least one surface of the reinforcing fiber substrate via an interlayer having a cover factor of 90%-100% and comprising at least one woven fabric. The process diminishes pinhole generation in the skin layer in RTM, and can reduce the necessity of a repair step in, e.g., a painting step as a later step, thereby improving productivity.

Abstract: A system for self-repairing matrices such as concrete or cementitous matrices, polymeric matrices, and/or fibrous matrices, including laminates thereof The system includes repair agents retained in and/or on vessels, such as hollow fibers, within the matrix. Upon impact, the vessel rupture, releasing the chemicals. For multi-layer laminates, the systems provides a total dynamic energetic circulation system that functions as an in situ fluidic system in at least one layer or area. The energy from the impact ruptures the vessels to release the chemical(s), and mixes the chemical(s) and pushes the chemical(s) and/or resulting compound through the matrix. The repair agents can withstand high temperatures, such as the heat of processing of many laminates, e.g., 250-350° F.

Abstract: The present invention provides a method for controlling the thickness of composite laminates cured on closed angle tools. The invention utilizes a peel ply rather than a breather during the preparation for cure of laminate parts having a substantially uniform initial thickness. This method allows composite parts to be formed with greater uniformity and without the need for extra hardware. The composite part formed by the above method may find use in a wide variety of applications, including, for example, automotive and aerospace applications. Thus, for example, a composite part formed in accordance with the present invention is ideally suited for use as a shear tie in a commercial aircraft, which are used to secure the inner framework of the aircraft to the airplane skin.

Abstract: The apparatus comprises a mold assembly including at least one bore therethrough having a cavity therein defining the shape of the finished microneedle shape to be formed therein. The bore has an inlet opening and an exit opening. The apparatus also comprises means for locating the polymer to be formed at one end of the cavity and means for introducing fluid into the inlet opening of said bore and into the cavity. The apparatus also comprises exhaust means communicating with the exit opening of the bore, so that introducing the fluid through the polymer causes the polymer to assume the shape of the cavity and the fluid forms a hollow channel to define a needle-like structure in the polymer as the fluid is exhausted through the cavity and the bore.

Abstract: A process for manufacturing a piece made of composite material that includes fibers that are immersed in a resin matrix, whereby the piece is placed in a first chamber with at least one flexible wall. The process includes a thermal cycle with essentially a first phase (50) at a first temperature during which the resin is liquid or in the “gel” state, and then a second phase (52) at a second temperature that is higher than the first during which solidification of the piece takes place by polymerization of the resin. An external pressure is applied to the outside of the first chamber and an internal pressure is generated inside the first chamber, wherein during the first phase (50), the relative internal pressure is less than 0 during a first period, and then greater than 0 during a second period preceding the beginning of the polymerization for reducing the porosity rate.

Abstract: A family of functionalized polymers is provided capable of forming membranes having exceptional OH? ionic conductivity as well as advantageous mechanical properties, which may be applied to membranes including such polymers for use in, e.g., AEMFC/HEMFC fuel cells. Preferred functional groups include a quaternary phosphonium, and the polymer may specifically be (tris(2,4,6-trimethoxyphenyl) phosphine)3 functionalized phosphonium polysulfone hydroxide, ECL-PVBC-QPOH, or QPOH based on any of the commercial polumers including polycarbonate (PC), poly(2,6-dimethyl-1,4-phenylene oxide) (PPO), polyetherimine (PEI), poly(ether sulfone) (PES), poly(phenylene sulfoxide) PPS, poly(ether ether ketone) (PEEK), or polybenzimidazole (PBI), polyvinyl chloride (PVC). An ionomer membrane may include polysulfone based TPQPOH, ECL-PVBC-QPOH, and/or PPO.

Abstract: The invention described herein relates to a method by which a reservoir having desired end connection profiles may be made using shape memory characteristics of crosslinking to compressively seal the connection profiles into the reservoir.

Abstract: The present invention provides a method for manufacturing a hollow composite structure by forming a prepreg product using a plurality of prepregs, forming a soft coating layer on an inner surface of the prepreg product, and compressing the prepreg product by applying pressurized air to the coating layer and, at the same time, applying heat to the prepregs.

Abstract: Processes for manufacturing hollow structures such as spars for helicopter rotor blades, fixed wings for aircraft, and other aerostructures can include the provision of a path for gases to exit the material from which the spar is formed as the material is heated and cured, to help eliminate voids within the material caused by the presence of such gases.

Abstract: A vulcanization apparatus and method for vehicle wheel tires, includes at least one prevulcanization work station to conduct a prevulcanization of a radially internal portion of the tire and at least two vulcanization work stations wherein the remaining part of the vulcanization of the whole tire is carried out.

Abstract: A method and apparatus for curing a thermosetting material. The method comprises heating the material with a liquid heating medium; measuring an electrical or optical property of the material with a cure sensor; and regulating the temperature of the liquid heating medium in accordance with the measured property of the material.

Abstract: The present invention generally relates to a mold assembly (32, 34) and a method of using the mold for the manufacture of composite parts which, more particularly, are generated from a strengthener in a generally solid phase and a matrix in a generally liquid phase. Various types of molds and processes may be used in order to impregnate a strengthener with a matrix such that a composite part may be manufactured, but the efficiency rate and the duration of the manufacturing process significantly varies depending on the chosen type of mold and process. The present invention relates to a mold assembly and to the manufacture of composites by using the mold assembly which includes the injection of the matrix in the mold assembly containing the strengthener and a deformable member (36) which favors the impregnation of the matrix toward the strengthener.

Abstract: A method for manufacturing a base tire ensuring a cure-molding of a green tire therefor without overcure or undercure in the thin-walled shoulder portions of the tread region and the bead regions, a curing machine that preferably enables the base tire manufacturing method, and a base tire thus manufactured are provided. To that end, a base tire is enclosed within a curing mold, the side regions of the base tire are heated by a first heating means, the tread region of the base tire is heated by a second heating means, and a cure-molding is performed such that the amount of heat given to the tread region by the second heating means is smaller than the amount of heat given to the side regions by the first heating means.

Abstract: A forming tool and method for its use with flat pre-preg composite laminate assemblies which incorporates a mandrel segmented into multiple forming blocks, the forming blocks sized to receive a draped composite laminate assembly with all portions of the composite laminate assembly spaced from a shaping surface on each block. A spline plate engages the shaping surface of the forming blocks to provide a neutral axis for maintaining the entire composite laminate assembly in tension during forming. In the exemplary embodiments, the draped composite laminate assembly is formed to the forming blocks from the flat composite laminate assembly and maintained in contact with the forming blocks using a vacuum bag. The mandrel forming blocks are then displaced to a desired curvature on the spline plate.

Abstract: In accordance with the present invention, there is provided a method for the forming or curing of polymer composites, the method including the step of: forming or curing the polymer composite in the presence of water vapor at about atmospheric pressure.

Abstract: A method for manufacturing an elongate stiffening element and a rigid shell structure integrated with at least one elongate stiffening element. The method includes providing a preformed, form-stable reinforcement member, which has a hat profile with two inwardly directed, opposing flange portions, covering the reinforcement member with a curable composite material to form an external hat profile having outwardly directed flanges, and integrating this assembly with either a curable or preformed shell structure of composite material.

Abstract: A tire mold has an annular rough surface molding portion extending along a circumferential direction in a region of a tire molding surface for molding a side wall portion. The rough surface molding portion is provided with a projection extending spirally along a circumferential direction at a protruding height between 5 and 300 ?m.

Abstract: A method for making a honeycomb composite structure wherein the method allows for fluid flow from cells of a honeycomb core during a cure process. More specifically, the method involves forming one or more vents in a skin of the structure, which are preferably filled with venting wicks, to allow for fluid flow before being sealed by the polymer matrix during a skin bonding process. Additionally, the structure preferably comprises a scrim that allows for fluid flow between multiple cells of the honeycomb core. The honeycomb composite structure produced according to this process comprises, among other things, a sealed venting region that comprises a polymer matrix and fibers that are transverse to the skin.

Abstract: A method and an apparatus for conforming a blank onto forming surface sections of a forming tool by drawing a vacuum against an elastic vacuum bag for transmitting forming forces from the elastic vacuum bag to the blank. The elastic vacuum bag includes at least one bag section having a different stiffness than other bag sections. The at least one bag section is an elongated bag section having a stiffness larger than that of surrounding bag sections. The location of the elongated bag section of the elastic vacuum bag corresponds, when the elastic vacuum bag after completion lies against the forming surface sections having the blank in between, with an elongated forming surface section of the forming tool where the blank requires a forming force being larger than that of the surrounding bag sections.

Abstract: A method for producing a molded wood material part with the use of a basic wood material and a heat-curable binding agent by way of pressing. In order to cure the binding agent, heat is transferred into the molded wood material part in the form of a steam shock. In order to shorten the pressing time, the process air pressure prevailing in the pressing chamber is increased before the transfer of heat in the form of a steam shock in relation to the atmospheric air pressure prevailing outside the pressing chamber, but without also supplying moisture, in particular in the form of water vapor, to the molded wood material part.

Abstract: A cured sandwiched article may be used to enhance a portion of a vehicle. In some embodiments, a cured sandwiched article may include a core sandwiched between one or more backing layers and one or more top layers cured to conform to a surface of a vehicle. A cured sandwiched article may be made by steps including shaping a core, positioning the core between one or more backing layers and one or more top layers to form the sandwiched article, and curing the sandwiched article. A cured sandwiched article may be connected to a surface of a vehicle by providing adhesive to a bottom surface of the cured sandwiched article, positioning the cured sandwiched article on a surface of the vehicle, and curing the adhesive. In some embodiments, the cured sandwiched article may include a plurality of fiber-optic fibers.

Abstract: A method for fabricating stringers is provided. The co-cured composite stringer includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.

Abstract: A method of making a fenestration framing member includes providing a core of size and shape corresponding to the desired size and shape of the fenestration framing members. A fiberglass mat is placed on the core to form a fiberglass-engaged core, and resin is vacuum infused into the mat to form a fenestration framing member that includes fiberglass-reinforced resin engaging the core. The starting core and the final fenestration framing member preferably are of curved geometry lengthwise of the core and member. The step of vacuum infusing resin into the mat surrounding the core preferably is carried out by placing the fiberglass-engaged core into a vacuum enclosure, preferably a vacuum bag, and connecting the vacuum enclosure to a vacuum source and a resin source. In one embodiment of the disclosure, the mat surrounds the core so that the core is part of the fenestration framing member.

Abstract: The invention relates to a process for manufacturing a water reservoir with an inlet and an outlet which are compressively sealingly engaged with the water reservoir tank by utilizing the latent heat of extrusion of the extrudate to bond with the exterior surfaces of the inlet and outlet profiles.

Abstract: A radiation crosslinked (50 kGy), pressure-treated UHMWPE material has been developed by applying compressive force on a crosslinked polymer in a direction orthogonal to an axial direction. The deformed material is then cooled while held in a deformed state. The resulting material is anisotropic, with enhanced strength oriented along the axial direction. The directionally engineered material is oxidatively stable even after four weeks of accelerated aging in a pressure vessel containing five atmospheres of oxygen (ASTM F2003). Because of its oxidative stability, the deformation processed material is a suitable candidate for air-permeable packaging and gas sterilization, which has thus far been reserved for remelted highly crosslinked UHMWPEs.

Abstract: A method of making a fenestration framing member includes providing a core of desired cross section and geometry lengthwise of the core. A fiberglass mat is placed around the core to form a fiberglass-enclosed core, and resin is vacuum infused into the mat to form a fenestration framing member that includes fiberglass-reinforced resin enclosing the core. The starting core and the final fenestration framing member preferably are of curved geometry lengthwise of the core and member. The step of vacuum infusing resin into the mat surrounding the core preferably is carried out by placing the fiberglass-enclosed core into a vacuum enclosure, preferably a vacuum bag, and connecting the vacuum enclosure to a vacuum source and a resin source.

Abstract: A net shaped latex vacuum bag as used in the fabrication of composite structural parts having complex shapes. Liquid latex is first allowed to air dry in the form of a thin flat, flexible sheet. The latex sheet is then vacuum formed over a tool having the complex shape of the part to be fabricated and assumes the shape and configuration of the tool's outer surface. The latex sheet is then rapidly cured at an elevated temperature, so as to permanently assume the part's shape for subsequent use in forming composite structural parts of the same complex shape. In one embodiment, the latex sheet may be formed on the tool by dipping the tool in liquid latex, allowing the latex coating to dry, and cutting the dry latex coating to permit separation of the tool from the latex coating which is then used in composite part fabrication.

Abstract: The present invention relates to a process (10) of forming a covering configured to be worn by a human or animal. The process (10) comprises the step of applying uncured silicone rubber to a textile substrate (14), the textile substrate comprising an elastic fibre that allows the textile substrate to stretch elastically, the textile substrate defining the general form of the covering. The process also comprises part curing the silicone rubber (16) such that the silicone rubber is sufficiently cured that the integrity of the silicone rubber can be substantially maintained and yet the silicone rubber is sufficiently uncured that a surface of the silicone rubber is impressible. The process (10) then comprises impressing a pattern on the surface of the part cured silicone rubber (20, 22).

Abstract: The invention relates to a process for the manufacture of composite products made of thermosetting plastic comprising a first pressure chamber (8) and a second pressure chamber (10). Each of the pressure chambers is provided with an elastically deformable chamber wall (12, 14), a mould configuration comprising at least one tool (16) with a mould chamber capable of accommodating a prepreg material (18). The pressure chambers are oriented with the elastically deformable chamber walls(12, 14) opposing one another, so that, when the press is operated with the mould configuration (16, 18) situated between the elastically deformable chamber walls (12, 14), the latter are at least partially in contact with one another with a pressing force (F) in a moulding stage.

Abstract: A vulcanisation apparatus and method for vehicle wheel tyres, includes at least one prevulcanisation work station to conduct a prevulcanisation of a radially internal portion of the tyre and at least two vulcanisation work stations wherein the remaining part of the vulcanisation of the whole tyre is carried out.

Abstract: A pick guard for a guitar comprises a main body having a front surface and a back surface, and a peripheral edge adjoining the front surface and a back surface. At least a substantial portion of the main body comprises a doming mixture. There is also a guitar contact portion having a front surface and a back surface, and a peripheral edge adjoining the front surface and a back surface. An adhesive is on the back surface of the guitar contact portion. The front surface of the guitar contact portion may include a graphic image.

Abstract: A device for the manufacture of a cast, in particular a dental aid from a preheated workable substrate. The device comprises a hollow body having an essentially flat first side being provided with holes which first side is arranged to receive a model from which a cast is to be made. Said first side is adapted to cooperate with a holder-on, which seals the substrate against said first side. The body cooperated with a vacuum source that the cooperation is achieved through one to the body belonging connection being connectably arranged to an external vacuum source.

Abstract: A thread or other element for bonding fibers in a fibrous reinforcement for use in a fiber composite is such that it is at least degraded in the course of the production of said fiber composite.

Abstract: A continuous process for making a thermoplastic article comprises extruding a sheet of thermoplastic and contacting the sheet with a mold surface while the sheet is in a substantially non-oriented state. The mold surface is selectively heated and/or cooled during thermoforming to maintain the sheet in a molten or thermoformable state. A stripper plate adjacent to the mold surface is maintained at different temperature for inducing a predetermined degree of crystallinity to the sheet, for increasing web stiffness and improving web alignment, and optionally for assisting in the separation of the articles from the mold. A continuous apparatus for making thermoformed articles has co-extruders for extruding at least two distinct layers, which can have dissimilar properties (e.g., polar and non-polar), and a temperature controlled molding surface. Preferred thermoplastic compositions of the present invention have improved toughness and retained intrinsic viscosity.

Abstract: A plastic blow molded container having a central vertical axis constructed in accordance with the present invention includes a cylindrical upper rim, an oriented neck portion, a lower body portion, and a closed base portion. The upper rim of the container includes a top surface having a planar inner edge and an outer edge. The inner edge is generally flat and perpendicular to the vertical axis of the container and the outer edge may be curled or curved to provide additional rigidity. The oriented neck portion depends from the upper rim and includes a means to accept a closure, such as a set of integral threads. When viewed in vertical cross section, the outer vertical line formed by the outer axial points of said means to accept a closure is substantially parallel to the vertical axis of the container. The lower body portion is generally cylindrical over the majority of its vertical length. The closed base portion supports the container and depends from the lower body portion.

Abstract: Bicycle frame components without laps made by a method comprising; shaping a fluid-removable core in the general form of the component, placing a flexible inflatable bladder around the core, wrapping over the assembly of core and bladder at least one ply of fiber impregnated with a curable resin, forming a cured part by inflating the bladder while the assembly of core, bladder, and impregnated fiber is in a mold to force the plies against the inner surfaces of the mold, such that compaction of the fiber against the mold is predominantly from the bladder inflation and not from the core, and heating to cure the resin to form a cured part, removing the bladder and the fluid-removable core from the interior of the cured part by disintegrating the fluid-removable core with a fluid sufficient to allow removal of the core and the bladder.

Abstract: A new and improved apparatus and method for producing torsion cords comprising the steps of: (1) casting a torsion cord of a rubber composition, the mold having a high pressure resistant cylindrical wall and opposite closed ends, (2) efficiently curing the rubber composition at a moderate temperature and high pressure for an extended period of time in the mold, (3) reducing the pressure in the mold, and (4) removing the molded torsion cord from the mold. An improved torsion cord manufactured by the method of the invention is also provided having closely controlled dimensions and improved physical properties with fewer process control procedures.

Abstract: A method for blow down hydroforming sheet material includes hydraulically inflating a seal intermediate a pair of wall members and disposed between a platen and a table in circumscribing relationship with a cavity formed in the platen to seal the cavity and injecting gas into the cavity to urge conformance of the sheet material with a mold placed upon the table.

Abstract: A multilayer plastic film has at least two inner polyvinylidene chloride (PVDC) layers, outer layers comprising a polyolefin homopolymer, copolymer or ionomer, and bonding layers between the PVDC layers and between the PVDC layers and the outer layers.

Abstract: A method for manufacturing a composite shaft comprising providing an impregnated fibrous material comprising a fiber impregnated with a hardenable polymeric material, forming an impregnated fiber preform by wrapping the impregnated fiber material around a shaped pressurizable bladder, the bladder having outer dimensions to form a preform dimensioned closely to the final dimensions of the shaft and dimensioned to allow placement of the assembly of the bladder and the impregnated fiber preform into female tooling, placing the assembly of the bladder and the impregnated fiber preform into the female tooling, pressurizing the bladder to press the impregnated fiber against the tooling, and heating the tooling to form a hardened composite of the polymeric material and the fiber while maintaining pressure in the bladder, releasing the pressure in the bladder, and removing the bladder from the interior of the shaft.

Abstract: A process for producing deformable acrylic panels with increased resistance to abrasion and scratching preferably for sanitary articles to be produced by the deep-drawing process. Immediately prior to the deep-drawing step, a type of lacquer is applied to an acrylic panel. The lacquer contains dispersed nanoscale particles preferable of an inorganic material. The semifinished acrylic panel is heated and subsequently deep-drawn. The lacquer coating is applied to the semifinished acrylic panel with the help of rollers or a doctor blade. In addition, the lacquer coating can be applied by immersing or flooding the semifinished acrylic panel.