Abstract: A method for forming an article includes providing a sheet of material, optionally conditioning the sheet with a surface of a roller, forming the sheet to provide a web, and separating an article from the web to provide the article. An apparatus adapted to form the article from a sheet is provided.

Abstract: A method for producing plastic containers includes feeding plastic preforms to a shaping unit, shaping the plastic preforms to plastic containers, and filling the plastic containers with a liquid. The method further includes closing the plastic containers with plastic closures, wherein the plastic closures are produced of a plastic material and are heated during the manufacturing process.

Abstract: This disclosure relates to a method and apparatus of preparing a molded article, and more particularly to a method and apparatus of automated molding using male molds and thermoplastic sheets in which the thermoplastic sheets are systematically draped across the mold contour.

Abstract: A vacuum barrier system for curing a composite part may include a bag carrier and a compliant, relatively thin film bladder formed over the bag carrier to function as a vacuum barrier. The bag carrier may be configured complementary to the composite part. The bladder may seal the bag carrier therewithin.

Abstract: A connecting port arrangement for use in an apparatus for producing a composite material component comprising a base member attached to a surface of a foil adapted to seal a mold of the apparatus for producing a composite material component. The base member is provided with a channel extending therethrough. The connecting port arrangement further comprises a punch member adapted to be inserted into the channel formed in the base member and provided with a cutting device suitable to cut at least one opening into the foil.

Abstract: A sheet for thermoforming made of a polylactic acid resin composition containing a polylactic acid-based resin, a plasticizer, and a crystal nucleating agent, wherein the sheet has a thickness of from 0.1 to 1.5 mm, and wherein Re (cal) calculated by the following formula (A): Re (cal)=Re (obs)/d×10?6 (A), wherein Re (obs) is a phase difference (nm) measured at a wavelength selected from wavelengths of from 380 to 780 nm, and d is a thickness (mm) of the sheet, is within the range of 0.001×10?3?Re(cal)?1×10?3. The sheet for thermoforming of the present invention has a wide moldable temperature region, so that the sheet can be suitably used in various applications such as food containers, packaging materials for daily sundries and household electric appliances, industrial trays of industrial parts, and the like.

Abstract: A composition for making a cast, thermoformable sheet or slab, comprising: a syrup comprising: about 30-40% SSI—acrylic pre-polymerized syrup at 20% solids; about 30-40% MMA—methyl methacrylate; about 2-3% BA—Butyl acrylate; about 1-15% acrylic chips; and about 1-15% rigid particles with a mean diameter of about 0.5-2000 ?m. The rigid particles may preferably comprise a polymeric material such as poly allyl diglycol carbonate particles. A method for producing a thermoformed article having a textured surface comprising mixing the syrup as above; swelling the acrylic chips; degassing the syrup; heating the syrup; casting the syrup into a sheet; and thermoforming the cast sheet against a mold.

Abstract: Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts and allowing a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish.

Abstract: A tamper-resistant container with tamper-evident features which includes a cover portion defining a peripheral flange, a base portion defining an upper peripheral edge, and a hinge joining the cover portion with the base portion. The upper peripheral edge includes an upwardly projecting bead extending substantially about the perimeter of the base portion that is configured to render the peripheral flange of the cover portion relatively inaccessible when the container is closed. The hinge includes a frangible portion for facilitating the removal of the cover portion from the base portion to open the container.

Abstract: A method for shaping dry preform material prior to resin infusion is disclosed. The starting material to be shaped is a preform blank (e.g. flat sheet) of dry, fibrous material. The shaping process is a vacuum forming process that relies on controlling the vacuum pressure and deformation speed to produce a shaped preform with three-dimensional configuration. The purpose of the shaping process described herein is to enable an automated process to replace the conventional hand lay-up operation.

Abstract: Soluble pouches are formed on a continous motion rotating thermoforming machine having cavities in the surface of a drum into which a web of polymeric film is drawn by a vacuum to form pockets. The pockets are filled with one or more components and closed by a further web of polymeric film. Shrink-back of the polymeric film within the cavities is reduced by heating the cavities with heaters.

Abstract: Oral appliances, methods of making oral appliances, and bite registration devices for use in making oral appliances are provided. An oral appliance includes a lower segment, and upper segments. The upper segments are operably connected to the lower segment using threaded elements. Rotational manipulation of the threaded elements causes the upper segments to be displaced horizontally relative to the lower segment about the lengths of the threaded elements, and the lengths of the threaded elements are substantially parallel to each other. A bite registration device for use in making an oral appliance includes a top surface including a protrusion and a bottom surface including a receptacle configured to receive the protrusion. The device is configured to be maintained in stacked relation to a like configured second bite registration device by mating the protrusion of the bite registration device with a receptacle of the second bite registration device.

Abstract: A process for manufacturing a plastic fuel tank including: introducing a parison into mold cavities; introducing a core inside the parison, where the core is first fitted with a swirl pot having a housing for the pump; closing the mold so that the cavities come into leaktight contact with the core; pressing the parison against the cavities by blowing through the core and/or applying a vacuum behind the cavities; fastening the swirl pot to the parison using a device attached to the core; molding the parison by blow molding and/or thermoforming; unmolding the tank, and mounting a pump in the housing of the swirl pot. The mounting of the pump is achieved by way of an intermediate part, the external shape of which is standard and complementary to that of the housing, and the internal shape of which is adapted to the pump.

Abstract: Apparatus for processing a workpiece comprises a base adapted to have a workpiece placed thereon. A vacuum bag is placed over the workpiece, and the bag is sealed to the base using inner and outer seals. The inner and outer seals are spaced apart from each other to form a channel therebetween. A vacuum port coupled with a vacuum source is used to evacuate air from the channel.

Abstract: A custom mouthguard may be formed from a multiple layer assembly including an ethylene vinyl acetate/thermoplastic polyurethane layer, an ethylene vinyl acetate layer and an intervening impact shield and elastomeric framework. The elastomeric framework may include one or more posterior occlusal pads. The custom mouthguard may be molded to a positive mold of an individual's upper teeth and gums.

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 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 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 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: Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts and allowing a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish.

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 forming a circuit board is provided. The method includes forming a circuit board substrate (112) from a circuit board material. The method also includes positioning the circuit board substrate on a rigid structure (114) having a three dimensional contoured surface (300). The method further includes applying heat and applying pressure to the circuit board substrate to at least partially conform the circuit board substrate to the three dimensional contoured surface. If the circuit board substrate (112) is a clad circuit board substrate, then a circuit pattern is formed on the circuit board substrate prior to the steps of applying heat and applying pressure. However, if the circuit board substrate (112) is an unclad circuit board substrate, then a circuit pattern is disposed on the circuit board substrate after the steps of applying heat and applying pressure.

Abstract: A forming tool (100) for and a method of making a three dimensional composite component using double diaphragm forming. The forming tool (100) comprises a forming side having two or more regions of changing profile and one or more through holes associated with each region, the through holes exit on the forming side and are connectable to one or more vacuum sources such that vacuum can be selectively and discretely applied to each region.

Abstract: A method and apparatus for manufacturing a molded product that includes a resin coating step of coating molten resin onto a forming mold having a minute uneven portion on the surface thereof, a compressing step of pressing the molten resin using the forming mold to thereby arrange the shape of the molded product, and a solidifying step of cooling and solidifying the molten resin. The resin coating step supplies the molten resin to a resin coating device including a discharge port and, while moving the resin coating device, discharges the molten resin onto the minute uneven portion of the heated forming mold from above to fill the molten resin into the minute uneven portion substantially in the same shape and thickness as those of a final shape of the molded product.

Abstract: A process for forming shaped three-dimensional products is described made from a composition containing at least one filler and an aromatic liquid crystal polymer. In one embodiment, the process includes forming a substrate such as a film, a sheet or a tube, through an extrusion process. Once the substrate is formed, the substrate is then heated and fed to a shaping process. The shaping process may comprise a thermal forming process or a blow molding process. In order to form the three-dimensional products, the aromatic liquid crystal polymer has a high heat of crystallization, a high melt temperature and/or a high melt viscosity.

Abstract: A device for making a seamless, anatomically contoured, prosthetic device for supporting or maintaining the position of mammalian tissue, organ or structure or a replacement thereof, such as a breast implant, includes a support plate, an ironing plate or a clamping plate and a core plate, each of which is made from a thermally conductive material. The support plate and the ironing or clamping plates have openings formed through the thickness thereof. The core plate has a core extending outwardly from a lower surface thereof which is received through the openings in the ironing or clamping plate and the support plate.

Abstract: A method for producing appliance cabinets and the like, particularly a refrigerator cabinet having a double wall, whereby a polymeric sheet made plastic by thermal action is vacuum formed in a mold. The mold comprises a central male portion adapted to form the cavity of the cabinet and an annular female portion adapted to form the double wall of the cabinet, a plug assist device being used in order to drive the sheet in the female portion of the mold.

Abstract: Using a metal mold (20a) consisting of a convex mold part (21a) and a concave mold part (22a), a molding material (14) is placed between a pair of coating films (12), and after clamping, the molding material (14) and the coating film (12) are heated and molded to make a biodegradable expanded molded article, and at the same time, the coating film (12) is softened and pressure-bonded to a surface of the biodegradable expanded molded article. An exhaust hole (31a) and (32a) are provided on the convex mold part (21a) and the concave mold part (22a), respectively. At the time of heating and molding, gaseous matter existing between the coating film (12) and a surface of the metal mold (20a) is discharged out of the metal mold (20a) through the exhaust holes (31a) and (32a).

Abstract: Apparatus and methods for molding composite bodies into composite parts using pressure. A lower inflexible mold is combined with an elastic upper mold layer to form a molding cavity in which the composite body to be molded is placed. An elastic pressure layer is used in combination with the upper mold layer to form a pressure chamber. A flexible expansion control layer is used to limit the increase in surface area of the pressure layer during pressurization. A perimeter retention lock is provided to prevent the perimeters of the elastic and flexible layers from moving inward or away from the lower mold during application of pressure to the pressure chamber.

Abstract: A molding process and apparatus suitable for use in molding processes, including rapid prototyping processes and short run production processes. The molding process and apparatus entail the use of a reconfigurable screen tool having a housing defining a manifold cavity and a plurality of substantially parallel pins, each having a head protruding from the housing and a shank protruding into the housing. The heads of the pins define a screen surface through which air is able to flow, for example, through gaps between adjacent heads or through internal passages within the pins. The process further includes axially moving the pins to configure the screen surface, preventing further axial movement of the pins relative to each other, and then drawing a vacuum within the manifold cavity and creating a vacuum at the screen surface.

Abstract: The present invention provides a method of manufacturing high-melting-tension heat-resistant transparent or opaque sheets, boards, and molds from polyethylene terephthalate (PET). The method is characterized in that a mixture of: (1) PET polyester whose melt flow rate (MFR) is 45-130 g/10 minutes (a); (2) coupling agent master batch (f) comprising coupling agent (d) and substrate (e), wherein coupling agent (d) is a mixture of compounds containing 2 epoxy groups (b) and compounds containing 3 or more epoxy groups (c); and (3) catalyst master batch (i) comprising coupling reaction catalyst (g) and substrate (h); is melted in a reaction-extruder to give PET polyester whose MFR is 40 g/10 minutes or less.

Abstract: A cover for a dental tool holder including a cover portion adapted for fitting over a receptacle of the tool holder so as to prevent direct contact between a dental tool and the dental tool holder when the tool is held within the holder.

Abstract: A method and a tool component for forming in an article of fiber-reinforced composite material at least one locally placed, sharply curved portion. A separate, substantially rigid pressure-transferring element configured with a profile corresponding to the at least one curved portion is placed over the laminate at the location of the at least one locally placed, sharply curved portion of the mold surface. A flexible membrane placed over the laminate and over outer, separated surfaces of the pressure-transferring element is evacuated to depress the laminate to fully conform to the shape of the mold surface.

Abstract: The present invention relates to a system to manufacture composite material parts comprising a supporting mandrel having at least one compacting zone configured to contain at least one composite material element to be compacted by applying a certain degree of vacuum. The system comprises also at least one compacting equipment comprising a frame having a plurality of interconnected arms along a predetermined perimeter, at least one vacuum bag attached to a side of the frame along its perimeter and configured to compact the element, at least one porous material attached to the vacuum bag along the frame's perimeter and configured to adhere in a removable way to the compacting zone and to impede the air influx during the compacting of element. The invention also relates to a compacting equipment and to a method to manufacture composite material parts.

Abstract: The method includes providing a mold apparatus (1) that includes, a first mold portion (11) having an interior mold surface (14) having a plurality of perforations (26) and a perimeter edge (17). The mold apparatus (11) further includes at least one tubular sheet retainer (35) having an exterior surface (38) having a plurality of perforations (41) and a longitudinal axis (44) that is oriented along at least a portion of the perimeter edge (17) of the first mold portion (11). Each tubular sheet retainer (35) is reversibly and controllably: (i) positionable along an x-, y- and/or z-axis relative to the perimeter edge (17); and (ii) rotatable around its longitudinal axis (44), toward and/or away from the perimeter edge (17). A heated thermoplastic sheet (95) is formed and contacted (while at a thermoformable temperature) with the interior surface (14) of the first mold portion (11) and the exterior surfaces (38) of the tubular sheet retainers (35).

Abstract: Providing a drinking lid with an under-lap between a valve base and a lid body. The valve is created with an “L” shaped exterior step around the valve side wall adjacent the wall bottom. A coining die stamps the L-shaped step producing a smooth side wall and forcing excess plastic material under a die-cut at the wall bottom creating a flange which under-laps the lid body.

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: An apparatus and method for tensioning material (12) over a mold (14), such as a cure tool, comprises a tensioning fork (10) consisting of two substantially parallel tapered legs (18,20) between which material (12) is disposed. A tensioning fork (10) is positioned at a first side edge (42) and proximate a first end edge (38) of the material (12). A first leg (18) of the tensioning fork (10) is disposed under the material (12), and a second leg (20) of the tensioning fork (10) is disposed over the material (12). When force is applied to the second leg (20), it pivots about the first leg (18) along the length of the legs, remaining parallel to the first leg (18), thereby pressing a portion of the material (12) against the mold (14).

Abstract: The method includes providing a mold apparatus (1) that includes a first mold portion (11) having a contoured and perforated interior mold surface (14), and a perimeter edge (17). The mold apparatus also includes a frame (35) that surrounds at least a portion of the perimeter edge (17) of the first mold portion (11). At least one sheet retainer (148) resides on the upper surface (38) of the frame (35). Each sheet retainer (148) includes a clamp portion (151) that faces towards (or in the direction of) the perimeter edge (17) of the first mold portion (11), and which includes a reversibly closeable clamp member (154) which defines in part a clamp interior (157). Each sheet retainer (148) is independently, reversibly and laterally attached to the upper surface (38) of the frame (35), such that each clamp portion (151) is reversibly and laterally positionable relative to the perimeter edge (17) of the first mold portion (11).

Abstract: A method of forming a shaped thermoplastic sheet is described. The method includes providing a mold apparatus (1) that includes, a first mold portion (11) having an interior mold surface (14) having a plurality of perforations (26) and a perimeter edge (17). The mold apparatus (11) further includes at least one sheet retainer (35) having an upper surface (38) having a plurality of perforations (41) and a longitudinal axis (44) that is oriented along at least a portion of the perimeter edge (17) of the first mold portion (11). Each sheet retainer (35) is reversibly and controllably: (i) positionable along an x-, y- and/or z-axis relative to the perimeter edge (17); and (ii) rotatable around its longitudinal axis (44), toward and/or away from the perimeter edge (17). A heated thermoplastic sheet (95) is formed and contacted (while at a thermoformable temperature) with the interior surface (14) of the first mold portion (11) and the exterior surfaces (38) of the tubular sheet retainers (35).

Abstract: A method and an apparatus for continuously producing elongated siding panels is disclosed. The apparatus includes a conveyor, a plurality of mold plates, and a die for extruding a sheet of material onto the mold plates. The mold plates are formed of a rigid material and positioned adjacent one another and supported by the conveyor for forming the elongated siding panels. Each of the mold plates has an upper edge portion and a lower edge portion with an intermediate portion therebetween. The intermediate portion has an aesthetic pattern for imparting the pattern to the sheet of material with the adjacent mold plates having different aesthetic patterns. The lower edge portion has a lower leg extending substantially perpendicular from the intermediate portion defining a horizontal plane and a projection portion between the lower edge portion and the intermediate portion extends beyond the horizontal plane for imparting a jagged pattern to the intermediate portion.

Abstract: The present invention provides a bottomed cylindrical container, comprising a body wall, a bottom wall, and a ring-shaped foot downwardly extending from the bottom wall, said container being produced by thermo-molding a resin sheet, characterized in that said foot is formed by folding an inner wall by compressed fluid to be fusion-bonded with an outer wall, so as to form the foot comprising the inner wall and the outer wall. The present invention also provides a bottomed cylindrical container, comprising a body wall having a grounding edge at a lower end thereof, and a bottom wall, said container being produced by thermo-molding a resin sheet, characterized in that said bottom wall connects with an upper edge of an inner wall produced by folding back the body wall along the grounding edge and by fusion-bonding it to an inner periphery of the body wall. In addition, the present invention provides the methods for thermo-molding these containers and their apparatuses.

Abstract: A method of manufacturing a reinforcing cloth of a seat pad includes: fixing a sheet on a mold having an outer shape substantially identical to a shape of the reinforcing cloth and provided with a plurality of air holes interconnecting an internal space with an outer surface; forming a closed space between the mold and a cover member by covering the sheet fixed on the mold with the cover member; heating the sheet; shaping the heated sheet into a shape following the outer shape of the mold by exhausting air from the closed space through the air holes; and demolding the sheet from the mold after removing the cover member.

Abstract: A container with a flange having excellent heat resistance and impact resistance in the lower part of the barrel portion and having excellent transparency in the wall despite the container is formed by molding an amorphous polyester sheet, and a method of producing the same.

Abstract: A thermoforming methodology for laminated thermoplastic sheets which preserves the class “A” finish and high gloss thereof. In a thermoforming process including heating followed by vacuum and opposing air pressure application, and then followed by application of chilled compressed air, control of spherulite formation using any of: addition of a nucleating agent to the paint film, using the chilled compressed air at a temperature of substantially about 32° F., heating to no more than about 311° F., selecting a paint film having a high melting point temperature, and selecting a paint film that is non-crystalline.

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: In a method for manufacturing a thermoplastic resin vessel, in which a cup-shaped vessel is thermally formed from a thermoplastic resin sheet by a plug, the method including the steps of: pre-forming a portion of the thermoplastic resin sheet corresponding to an orifice portion or a flange portion of the cup-shaped vessel; and clamping the pre-formed portion of the thermoplastic resin sheet to accomplish the forming. According to the manufacturing method, thickening of a vessel bottom part and warpage of the flange portion can be improved.

Abstract: The present invention provides a bottomed cylindrical container, comprising a body wall, a bottom wall, and a ring-shaped foot downwardly extending from the bottom wall, said container being produced by thermo-molding a resin sheet, characterized in that said foot is formed by folding an inner wall by compressed fluid to be fusion-bonded with an outer wall, so as to form the foot comprising the inner wall and the outer wall. The present invention also provides a bottomed cylindrical container, comprising a body wall having a grounding edge at a lower end thereof, and a bottom wall, said container being produced by thermo-molding a resin sheet, characterized in that said bottom wall connects with an upper edge of an inner wall produced by folding back the body wall along the grounding edge and by fusion-bonding it to an inner periphery of the body wall. In addition, the present invention provides the methods for thermo-molding these containers and their apparatuses.

Abstract: A thermoforming method and objects prepared using the thermoforming method are described. Non-self-supporting, polymeric films are initially formed into a three-dimensional shaped film on a male mold and then transferred to a female mold while being supported by the male mold. The three-dimensional shaped film can be further thermoformed, reinforced, or a combination thereof on the female mold. The resulting object has a substantially uniform thickness across a major surface. The method can preserve the surface quality of the polymeric film used to prepare the three-dimensional objects.

Abstract: A device for making panels with three-dimensional curvature from a sheet material, includes a forming impression (5) defined by a membrane (6) including an elastically stretchable skin (11), preferably in combination with a skeleton formed by a grid pattern of flexurally elastic battens (10) which are mobile in longitudinal translation relative to the skin, and a set of elements for selectively deforming the impression acting on the battens (10) of the membrane to impart thereto an adaptable three-dimensional curvature. The invention is particularly useful for making sails.