Abstract: An apparatus for molding a composite structure which includes an insert that is pervious to a flowable resin, and a mold having a cavity defining contiguous upper and lower portions. The upper portion is adapted to receive a fibrous pre-form, and the lower portion is adapted to receive the insert. The insert defines a volume to accommodate a pool of the flowable resin. Also, the insert preferably includes a plurality of fluid transferable elements. The fluid transferable elements preferably include a generally planar plate and an expanded metal pre-form, wherein the plate and the expanded metal pre-form are configured to facilitate resin flow in a direction generally orthogonal to a bottom surface of the mold to distribute the resin uniformly across the mold cavity.

Abstract: Systems, methods and apparatuses for manufacturing dosage forms, and to dosage forms made using such systems, methods and apparatuses are provided. Novel compression, thermal cycle molding, and thermal setting molding modules are disclosed. One or more of such modules may be linked, preferably via novel transfer device, into an overall system for making dosage forms.

Abstract: The present invention relates to an apparatus for continuous vacuum forming of a thermoplastic material between a pair of rotating flexible belts in which one belt includes a plurality of teeth, which are received in a plurality of indentations of the other belt. Each of the belts includes a mold, which forms a channel when the belts are adjacent to one another. A vacuum is applied to at least one of the flexible belts for drawing material received in the channel and alignment of the belts. Preferably, a vacuum can be applied to both of the belts for improved alignment. Each belt can include a plurality of apertures, which are in fluid flow communication with a plurality of perforations of a flat support belt positioned over a vacuum manifold.

Abstract: In accordance with the present invention, there is provided a process for forming a fiber-reinforced resin structure against a mold surface by vacuum bag forming. The process includes grooving the mold surface to form resin distribution conduits therein. A fiber-reinforced ply is distributed adjacent the mold surface. A flexible covering is placed over the fiber-reinforced ply and the mold surface to form a chamber therebetween. The chamber is evacuated. Resin is dispensed into the evacuated chamber such that the resin enters the resin distribution conduits and is thereby distributed about the ply.

Abstract: Vacuum assisted molding apparatus provides reliable sealing about the mold cavity while minimizing the area of the plant floor space occupied by the mold.

Abstract: A process for the production of water-soluble pouches. The process comprises the steps of drawing a first film into a mould to form a first compartment, adding composition to the first compartment, drawing a second film into the mould to form a second compartment which comprises a composition and, preferably, sealing. The first film is perforated and the second film is drawn into the mould by means of suction applied through the first film. This eliminates the need to align separately formed pouches or containers. This also reduces the total amount of film needed to produce a multi-compartment pouch. Furthermore, it is very easy to vary the film material used according to what properties are desired. Since the different compartments may require different properties this adds flexibility to the process.

Abstract: A reusable vacuum bag apparatus for use in a compaction operation by which composite parts are formed. The apparatus includes a flexible, inflatable support structure which is secured to a reusable flexible mat vacuum bag. When inflated, the support structure maintains the vacuum bag in the orientation it needs to assume when placed on a forming tool associated with a compaction apparatus. The support structure is formed by a plurality of intercoupled linear and curving tubing segments which form a grid-like support structure. The support structure is shaped in accordance with the configuration and contours of the reusable vacuum bag portion, which is in turn shaped in accordance with a forming tool. The support structure can be de-inflated, which allows the vacuum bag secured thereto to be stored in a compact arrangement when not in use.

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: A female mold vacuum forming apparatus and a method for using the female mold vacuum forming apparatus for providing improved draw depth capability. The female mold vacuum forming apparatus comprises a top contoured surface and a cavity having a cavity surface formed within the top contoured surface. The cavity surface defines part geometry having deep-draw sections. The top contoured surface defines open sections in the side surfaces of the mold adjacent to at least one deep-draw section to allow free formation of parts within said at least one deep-draw section.

Abstract: The present invention relates to a method of forming a bone composite, comprising: providing bone tissue; grinding said bone tissue to form ground tissue; molding the ground bone tissue into a bone composite; applying a binder to the bone composite; applying a vacuum to the mold, and optionally milling or refining the bone composite to the desired shape. The present invention also encompasses bone tissue composites made therefrom. The composites may be, for example, a bone pin, screw, or prosthesis.

Abstract: A novel materials technology has been developed and demonstrated for providing a high modulus composite material for use to 1000° F. and above. This material can be produced at 5-20% of the cost of refractory materials, and has higher structural properties. This technology successfully resolves the problem of “thermal shock” or “ply lift,” which limits traditional high temperature laminates (such as graphite/polyimide and graphite/phenolic) to temperatures of 550-650° F. in thicker (0.25″ and above) laminates. The technology disclosed herein is an enabling technology for the nose for the External Tank (ET) of the Space Shuttle, and has been shown to be capable of withstanding the severe environments encountered by the nose cone through wind tunnel testing, high temperature subcomponent testing, and full scale structural, dynamic, acoustic, and damage tolerance testing.

Abstract: A molding process for a composite article uses a textured film layer to shape the surface of the composite article. The film layer is placed in the mold with the textured film surface exposed and a composite material is placed over the textured film surface. Preferably, the film layer is vacuum-formed onto the mold to take the shape of the mold. As it cures, the composite article takes the shape of the textured film layer to form a textured article surface. After demolding, the film layer adheres to the article as a protective coating, but can be readily removed from the article to expose an underlying textured surface of the article.

Abstract: An automobile interior trim component includes a molded substrate laminated onto a cover sheet including a foam backing and a skin film having a surface texture. The cover sheet is preheated so the skin film is in a melted viscous liquid state above its melting temperature, and the foam backing remains in a solid elastic foam state below its melting temperature. The preheated cover sheet is mechanically pre-molded by a back mold into a front mold. Pressurized air is applied through the back mold, to blow-mold the cover sheet against the front mold, so the melted skin film reproduces a surface texture of the front mold surface while the solid foam backing acts as a buffer and air barrier layer. Vacuum is applied through the front mold surface. The mold is opened, a substrate is introduced, and the back mold then molds and thermally laminates the substrate against the foam backing of the cover sheet.

Abstract: For producing a structural component of fiber-reinforced material by a resin transfer molding process, a preform unit is inserted in a form tool including upper and lower metal molds enclosing the perform unit therebetween, without a seal between the molds. The preform unit includes a resin-impregnatable and curable preform body of reinforcing fibers, and an envelope that encloses the preform body and includes an envelope sleeve and closures with valves at the two ends thereof. The sealed envelope is evacuated around the preform body through one valve, and resin is injected through the other valve. The envelope prevents resin discharge from the unsealed form tool during resin impregnation of the preform body.

Abstract: A hermetically sealed, molded thermoplastic dispensing container is provided which includes a nozzle having a resilient and unitary annular bead about the periphery thereof. The nozzle is sized to receive the hub of a dispensing assembly in a mating relationship and the bead provides a secure friction fit and liquid seal between the hub and the nozzle. The method of forming a container with a nozzle having such a bead includes the use of seal molds having a groove conforming to the shape of the bead and a vacuum passage in communication with such groove and the step of creating a vacuum through the passage and the groove to pull a portion of a parison into the groove to form the bead.

Abstract: The invention is a method of making a foam filled honeycomb core structure comprising the steps of: 1) providing a honeycomb core billet; 2) reinforcing the honeycomb core with foam; 3) placing the foam filled billet in mold having a curved mold surface; 4) creep forming the foam filled billet to the general shape of the structure by applying a load to the foam filled billet; and 5) machining the creep formed billet to the actual shape of the structure.

Abstract: A method for forming complexly shaped composite laminate assemblies. A pair of dry fiber preforms are placed on a tool with a thin film adhesive layer therebetween. A vacuum bag encloses the preforms and the adhesive layer. The preforms are heated to a temperature sufficient to cause the adhesive to become viscous and to wet several plys of each of the preforms. The preforms are then allowed to cool slightly before resin is infused via a vacuum source through each of the preforms to thoroughly wet each of the preforms. The resulting joint formed at the bond line of the two preforms is stronger than what would be formed simply by adhering two otherwise completely formed preforms together because the dry fiber preforms, in connection with the heating of the preforms, allow wetting of several plys of each of the preforms at the joint area, rather than just the surface ply of each preform.

Abstract: A method for producing an insulated container using a modified blow molding process. A multi-layer parison is created that includes inner layer, a thermoplastic foamed resin central layer, and an outer layer. The parison is clamped between halves of female mold, and a gas, e.g., air, is briefly blown into the interior of the clamped parison section to expand the parison section to substantially against the outer walls of the mold. Vacuum is applied through the mold walls to hold the clamped parison section in place, and the gas pressure is released. By removing the gas pressure, the clamped parison section is permitted to mold without internal pressures. That is, the vacuum holds the parison section in place, without air pressure crushing, or pressing against, the inner layer of the parison. In this manner, the foamed central layer is free to expand.

Abstract: The present invention involves a carbon fiber-filled sheet molding compound and method of manufacturing the same. The invention comprises providing chopped automotive carbon fibers, a predetermined resin paste, a first carrier film, and a second carrier film. The method further involves coating substantially completely one side of one of the first and second carrier films with the predetermined resin paste to define a coated side, depositing the chopped automotive carbon fibers onto the coated side, and covering the deposited carbon fibers with the second carrier film to define a compactible carbon-filled laminate. The method further includes compacting the carbon-filled laminate to admix the resin paste with the carbon fibers between the films, whereby to form the automotive carbon fiber-filled sheet molding compound.

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 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 porous, water-absorbing fleece is made from crosslinkable biocompatible and biodegradable macromers. A solution of the macromers is frozen and vacuum-dried through lyophilization. The “fleece” formed by lyophilization is then crosslinked, for example by heat and/or an initiator of crosslinking. The resulting crosslinked material is highly water absorbent, readily swelling to at least its size before lyophilization, but retains macroporosity as well as the microporosity of a gel. Porosity and strength of the fleece can be controlled by initial polymer concentration and extent of crosslinking. The fleece materials can be used in different embodiments for applications in medicine and tissue engineering.

Abstract: A resin infusion mold tool system for use in a vacuum assisted resin transfer molding process with a subsequent pressure bleed step. The mold tool system includes a mold assembly having an outer mold line tool connected to resin supply lines and supplying resin to the preform. A plurality of inner mold line tools form a hard interface with the inner mold line of the fiber preform and are held to within tight tolerances by an external locating fixture. Excess resin is drawn out of the fiber preform using a vacuum bag connected to vacuum lines and disposed over the inner mold line tools but not between the tools and the fiber preform. The mold assembly is placed in an autoclave, the resin supply lines are detached and the autoclave pressurized to bleed additional resin out of the preform to raise the fiber volume of the composite structure.

Abstract: An apparatus for molding a composite structure which includes an insert that is pervious to a flowable resin, and a mold having a cavity defining contiguous upper and lower portions. The upper portion is adapted to receive a fibrous pre-form, and the lower portion is adapted to receive the insert. The insert defines a volume to accommodate a pool of the flowable resin. Also, the insert preferably includes a plurality of fluid transferable elements. The fluid transferable elements preferably include a generally planar plate and an expanded metal pre-form, wherein the plate and the expanded metal pre-form are configured to facilitate resin flow in a direction generally orthogonal to a bottom surface of the mold to distribute the resin uniformly across the mold cavity.

Abstract: A method is presented for maintaining a plate member in a flat state, including the steps of placing the plate member on a surface of a supporting member, the surface of the supporting member being in a flat state and having at least one hole penetrating through the surface, and sucking air from a back side of the surface of the supporting member to generate an airflow flowing from a front side of the surface towards the back side thereof via the hole so as to retain the plate member on the surface of the supporting member. In this manner, the plate member, such as disc substrates adhered together by using an ultraviolet curable composition, can be accurately maintained in a flat state without damaging the surface thereof.

Abstract: The invention provides blow molding methods and systems for polymer processing. The methods involve blow molding a parison of polymeric material using a variable blow pressure. The pressure is varied to produce high quality blow molded articles which may be formed of solid polymer or polymeric foam including microcellular material. In particular, foam articles can be produced at relatively low densities and/or with good definition. The blow molding systems and methods may be used to produce a variety of different types of articles including bottles, containers, cases, automotive parts, toys and panels.

Abstract: Article made of thermoplastic material, which article is rigid and at least partly heat insulating. The article includes a laminate in at least parts of the article. The laminate includes a first and a second layer of solid thermoplastic material (A) and an intermediate layer of expanded thermoplastic material (B) with an average density of 50-800 kg/m3. The thermoplastic materials (A) and (B) are the same or compatible materials. The article is manufactured according to a process comprising the steps a) forming of a solid outer layer, b) manufacturing of an intermediate expanded layer and c) the appendage of functional parts such as reinforcing profiles, guiding profiles, stacking profiles, hinge parts, pockets, label holders, profiles or holes for automatic handling, locking devices or the like.

Abstract: A process for manufacturing wet-felted and thermally bonded porous structures is provided to produce formed porous media for use in filters with improved filtration performance. The process includes the steps of forming a slurry with a primary media consisting of natural or synthetic fibers, a wet strength agent consisting of fibrillated fibers, and a binding agent; vacuum forming the slurry to produce a formed media; drying the formed media using a gas at a temperature below the melting temperature of the binding agent; bonding the formed media using a gas at a temperature above the melting temperature of the binding agent; and cooling the formed media using a gas at ambient temperature. The process produces a formed porous media with improved bonding which results in improved filtration performance.

Abstract: A method of making an elastic pad for a sole in footwear has the following steps. Form an elastomer, a positioning rod is extended from the elastomer, the positioning rod supports and positions the elastomer in a mold. Form gasbags, by enclosing the elastomer with heated plastic film in mold then close the halves of mold. An elastic pad is then formed. Trim the elastic pad along the pressed periphery which is formed by the mold closure on excessive plastic film.

Abstract: The invention relates to a method for recycling polyethylene terephtalate (PET) flakes, characterized in that the flakes are extruded and granulated under vacuum, after which the granulate is aftercondensed in a solid phase under vacuum. Extrusion is preferably carried out in differentiated vent zones and aftercondensation of the solid phase is dependent on temperature, vacuum and time spent in a tumble dryer. Said dryer ensures the even and careful mixing and constant viscosity of the PET product. Said method is used in particular for making PET beverage bottles.

Abstract: A method for manufacturing an E.V.A. foamed sports equipment includes preparing and stirring an E.V.A. foamable mixture, then integrally forming the foamable mixture into a sports equipment blank with a constantly reduced scale, the constantly reduced scaled sports equipment blank being placed in a reduced scaled heat forming mold to be heated at the temperature of 180° C., then opening the reduced scaled heat forming mold after a pre-determined period of time, the constantly reduced scaled sports equipment blank in contact with the air being expanded into a foamed sports equipment blank, then, placing the foamed sports equipment blank and ornamental strips into a constantly scaled pattern generating mold to be heat pressed and melted into a unity, the generating mold being evacuated so that the periphery of the foamed sports equipment blank is attached to the pattern generating mold so as to form a foamed sports equipment product with a precise knurl pattern being formed thereon.

Abstract: A method of forming fiber reinforced polymer matrix composite structures having a low volume fraction of fiber reinforcement and carefully controlled thicknesses is provided. The method enables the production of composite structures having a fiber volume fraction of less than about 0.5 through the use of vacuum bag molding, thereby eliminating the need for expensive closed molds, The method also eliminates the occurrence of “racetracking” of uncured resin during the resin infusion process.

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 method of manufacturing a non-woven material uses a contoured honeycomb drum with an outer microporous surface, more particularly with a contoured outer surface, for the manufacture of contoured non-woven fibrous materials. The method can use spunbonded, melt blown, or electro-static spun techniques for depositing solidifying filaments on the microporous surface such that the non-woven material conforms to the contour of the drum. The drum facilitates continuous production of non-woven articles with three-dimensional shapes such as surgical masks or pleated air filters. Airflow through the drum can be controlled with an internal adjustable manifold with independent valves to obtain non-woven material articles of various configurations and properties. In addition, efficiency can be improved by including turning vanes. Vacuum or pressure can be applied.

Abstract: A mold apparatus and method is used to form a solid injection molded plastic part having no internal voids, a Class A finish, a sink-free exterior appearance surface, and unevenly distributed structural detail extending from the opposite surface, the detail including free-standing reinforcement ribs, attachment bosses, and the like. In sequence, a seal groove in the mold cavity is reduced to a pressure below atmospheric (i.e., negative), a charge of hot thermoplastic is introduced into the mold cavity and seal groove whereby to form a gas seal ring, and pressurized gas is injected into the mold cavity. The pressurized gas forces the hot plastic from one mold half against the other mold half, and the gas seal formed by the plastic prevents gas on one side of the thermoplastic from reaching the appearance surface of the part.

Abstract: Apparatus and method for cooking snack food pieces features a drum-type fryer which transports individual, die-cut piece preforms through hot oil contained within a cooking tank defined between the periphery of the drum and a housing in which the drum is contained. Vacuum transfer and feed rollers transfer the individual piece preforms from a die-cutting roller assembly onto the drum for cooking, and a similar roller transfers the cooked snack food pieces from the drum to a take-away conveyor for subsequent, downstream processing. The pieces are retained by suction against molding surfaces of frying mold elements distributed over the periphery of the frying drum.

Abstract: A system and process is provided for producing spunbond nonwoven fabric. Two or more polymeric components are separately melted and are separately directed through a distribution plate configured so that the separate molten polymer components combine at a multiplicity of spinnerette orifices to form filaments containing the two or more polymer components. Multicomponent filaments are extruded from the spinnerette orifices into a quench chamber where quench air is directed from a first independently controllable blower and into contact with the filaments to cool and solidify the filaments. The filaments and the quench air are directed into and through a filament attenuator and the filaments are pneumatically attenuated and stretched. The filaments are directed from the attenuator into and through a filament depositing unit and are deposited randomly upon a moving continuous air-permeable belt to form a nonwoven web of substantially continuous filaments.

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 molded plastic component having enhanced surface finish is molded within a mold having at least one metal base, a mold cavity, and at least one self-lubricating surface layer which defines the plastic component within the mold cavity. The self-lubricating surface layer includes a porous metallic skin integrally connected to and extending from an interior surface of the at least one metal base and lubricating particles disposed on the skin and in pores of the skin. The lubricating particles are bonded together to form a sealed surface of the at least one self-lubricating surface layer such that the molded plastic component has the enhanced surface finish. The metallic skin includes a plurality of spaced, sinusoidally-shaped projections of autocatalytic nickel alloy. The lubricating particles are preferably submicron-sized particles of low friction fluoropolymers. The mold may be an injection mold, a compression mold, a blow mold or a vacuum mold.

Abstract: This invention relates to a solution casting process capable of decreasing uneven coating of a functional layer upon applying the functional layer onto a film surface, which comprises casting a solution of polymer dissolved in organic solvent into a film by extruding from a die onto a support, wherein the length of the film from the die opening to the landing of the film on the support is controlled to 3 to 40 mm.

Abstract: An apparatus for calibrating hollow chamber sheet extruded lines out of thermoplastic resin includes a vacuum housing and a planar intake area at a first end of the vacuum housing. The planar intake area is configured to receive the extruded line. Support rollers within the vacuum housing are configured to support the extruded line. The extruded line exits the vacuum housing through a planar outlet area located at a second end of the vacuum housing opposite the first end.

Abstract: High-strength parts are produced by first performing a stereolithography part generation process to create a polymer part having opposing interior surfaces. An uncured strength material is interposed between the opposing interior surfaces of the polymer part. The polymer part with the uncured strength material is then heated. The strength material is chosen to bond to the opposing interior surfaces during the heating step.

Abstract: This invention relates to methods and apparatus for manufacturing shaped polymeric articles by substantially continuous vacuum forming. The method includes providing a sheet of hot polymeric material which is disposed onto a rotating belt having a mold impression. Vacuum pressure is applied to the polymeric material through the belt so as to draw the hot polymeric material into intimate contact with the mold impression to form a patterned sheet portion and a remaining sheet portion. This method thereafter cools at least the patterned sheet portion below a heat deflection temperature of the polymeric material, forms the remaining sheet portion, and then cools the remaining sheet portion below the heat deflection temperature so that features other than the central pattern, such as nail and butt edges, can be mechanically worked into the polymeric sheet.

Abstract: A method for the production of molded bodies comprising foam particles is proposed in which the foam particles are shaped and welded together using microwave energy. The foam particles are accommodated in a foil-like bag and the bag is manually shaped or shaped through the use of a shaped mold with simultaneous change of the shape of the foam particles, and evacuated into a dense package. Microwave energy is subsequently used to melt together at least the surfaces of the foam particles. The method in accordance with the invention is particularly well suited as an economical manufacturing technique for packaging, in particular specialized packaging for models, small production runs, prototypes and the like.

Abstract: Processes are disclosed for producing plastic containers from thermoplastic sheets where the thermoplastic sheets are processed in parallel to form a low permeation plastic container. A plurality of thermoplastic sheets are progressively heated to a first temperature in a pre-conditioning stage. A group of the thermoplastic sheets are selected from the plurality of thermoplastic sheets and rapidly heated to a second temperature in a final heat stage. The group of thermoplastic sheets are then processed in a forming stage to form the low permeation plastic container.

Abstract: On carrying out a hole filling method for a printed wiring board having an interlayer connection hole, first and second printed wiring boards (1 and 2) are prepared, each of which has the interlayer connection hole. The first printed wiring board is placed on a bottom plate (7). On the first printed wiring board, a first hole guide plate (8) having a first guide hole formed at a position corresponding to the interlayer connection hole of the first printed wiring board is placed in such a manner that the first guide hole is coincident with the interlayer connection hole of the first printed wiring board. A hole filling resin (9) is superposed on the first hole guide plate. On the hole filling resin, a second hole guide plate (10) having a second guide hole formed at a position corresponding to the interlayer connection hole of the second printed wiring board is placed.

Abstract: In addition to a loading apparatus (10) for loading material through the upper mouth of the mold cavity (6), the unit comprises a blower device (30) for blowing air, means for moving said device while held a short distance from the upper surface of the material (B′) loaded into the mold cavity, such as to lift in a gauged manner a thin layer of material from the top thereof, and means (51, 55) for collecting the material lifted by the blower device (30), in order to remove it from the mold cavity. In particular, the blower device (30) comprises a relatively narrow, long blowing port (31) arranged to emit an air jet in the form of a thin sheet extending in a horizontal direction, and means (33, 34) for feeding compressed air to said blowing port (31), which is moved while maintained a short distance from the upper surface of the material (B′) loaded into the mold cavity (6) in order to lift a thin gauged layer of material.

Abstract: An apparatus and method for forming a densified carbon-carbon composite. The apparatus includes: a green part molding station for forming a green part; a carbonization station for carbonizing the green part; and an impregnation station for impregnating the carbonized part with a substantially curing by-product free, high carbon yield resin. The impregnation station includes a mold forming a sealed enclosure configured in the shape of the carbonized part for receiving the carbonized part and a vacuum source for evacuating the mold. At least one resin injection port is in the mold and a supply of substantially curing by-product free, high carbon yield resin is connected to the resin injection port for injection into the mold. In the preferred embodiment, the substantially curing by-product free, high carbon yield resin is a cyanate ester having a viscosity of less than about 100 cps at 250° F. and a carbon yield value of greater than about 60 wt. %.

Abstract: A method of forming an ophthalmic lens using a composite ophthalmic lens vacuum mold to quickly and inexpensively produce, on-site, multi-focal, prescription and non-prescription optical quality eyeglasses, with or without photochromic, and photochromic non-prescription (e.g., sunglasses, safety glasses, reading glasses, etc.) optical quality eyeglass via a vacuum remolding. The method further includes a rigid remolding process for forming the composite ophthalmic lens.

Abstract: A process for manufacturing a costume having semi-rigid costume components, and the costume itself. The semi-rigid costume components are capable of being sewn to fabric to form an integrated costume. An embodiment is shown in which the costume includes a semi-rigid muscular torso suitable for a superhero chestpiece. The sewn rigid component is formed from fusing a layer of fabric to a layer of foam and the resulting laminate is vacuum molded into a three-dimensional shape.