Abstract: To provide an apparatus and method for producing a resin film product from a thermoplastic resin in a stable manner without damage to the product, wherein the resin film product is thin and has a uniform, flat surface. A mandrel 7 that comes into proximity or contact with the surface of a moving resin film to guide the movement of the resin film when a resin film in continuous form is continuously produced, the mandrel comprising: a mandrel main body 71 having an opening; and a guide part 72 that is composed of an elastic member attached to the opening 71a and that can advance and retract relative to the resin film, and an apparatus and method for producing a resin film using the mandrel.

Abstract: A portable conduit bending frame assembly comprises a support member having a conduit support surface extending substantially perpendicular to a top surface of the support member. A shoe is attached to the top surface of the support member. The shoe has a first alignment surface extending substantially perpendicular to a second alignment surface. A conduit bending surface extends between the first and second alignment surfaces and has a substantially arcuate configuration. The conduit bending surface faces the conduit support surface. A heating device is arranged proximate the conduit support surface for heating a conduit prior to bending the conduit at least partially about the conduit bending surface.

Abstract: A process for forming linear, thermoplastic weatherseals into a bend position is provided which avoids buckling of the thinner surfaces of the weatherseal material. The process involves the use of a support insert which supports the thinner surfaces during the bending operation, and thus assists in preventing the deformation of the thinner weatherseal surfaces. The support is preferable constructed of a material which is unaffected by temperatures higher than the heat-deformation temperature used to set the weatherseal material into a bent configuration, and thus, the support insert retains its linear shape when removed from the bending press, and therefore, can be reused. An improved process for manufacturing bent thermoplastic weatherseal material results.

Abstract: A mandrel for composite fabrication includes an open cell foam carrier and at least one vacuum bag enclosing the open cell foam carrier.

Abstract: In at least one method for manufacturing a double-walled, thermoplastic tube with a connecting sleeve, which enables precise and complete moulding of the connecting sleeve by simple means, it is provided that a) a first tube (1) is extruded into a mould tunnel (4) comprising at least one row of moulds (5) guided on a path, b) the first tube (1) is given a corrugated shape in at least one first section and expanded into a connecting sleeve in at least one second section, c) a second tube (6) is extruded into the first tube and pressed against the corrugation troughs (8) of the first tube (1), d) while the first tube (1) is being given a corrugated shape and the second tube (6) extruded into the first, the space (A) between the two tubes (1, 6) is subjected to a pressure p1 that is above atmospheric pressure, e) the space (A) between the two tubes (1, 6) is subjected, at a specified time before or after expansion of the first tube (1) into a connecting sleeve, to an essentially constant pressure p2?p1 above atm

Abstract: A folding tool onto which one places a fortune cookie crepe and a fortune ticket, while the crepe is still soft and pliable, which one then bends at hinges of the tool in a specific sequence, to cause the folding of the crepe around the fortune ticket and into a traditional fortune cookie shape before the crepe begins to permanently harden into its thus-formed shape.

Abstract: A molding apparatus for patterning a workpiece includes a mold having a pattern to be transferred to the workpiece, with the pattern including recesses, a first support member for supporting the mold, and a second support member, arranged opposite to the first support member, for supporting the workpiece. A pressing mechanism brings the first and second support members close to each other and presses the mold and the workpiece together so as to transfer, to the workpiece, the pattern on the mold. Recessed portions are provided on at least one of a surface of the mold on the first support member side, a region of the first support member, and a region of the second support member. The recessed portions correspond to recesses in the pattern of the mold.

Abstract: A shutter assembly having at least one rigid edge and at least one hanger edge is described. The rigid edge provides stability to the shutter assembly and the hanger edge allows the shutter assembly to be mounted to a dwelling. The shutter assembly can be formed in an open mold from a cementitious slurry comprising gypsum cement and water. A reinforcing mat or fiber can be disposed in the mold and saturated with the cementitious slurry. A tool disposed adjacent the mold and including a plurality of rotatable sections can be used to form the rigid edge and the hanger edge.

Abstract: Disclosed herein is an apparatus for vulcanizing rubber, particularly for vulcanizing the ends of endless rubber belts. The apparatus disclosed herein is a lightweight and portable steam heated vulcanization apparatus which comprises upper and lower platens comprising hollow bodies having a rigid outer wall and a flexible inner wall and adapted to receive steam therein and transmit heat and pressure to a rubber belt placed between the flexible inner walls of the platens. A steam source is connected to the platens for delivery of steam and a plurality of connecting bolts pass through apertures in the platens and the belt material therebetween to align the platens and secure them together so as to apply pressure to the belt in combination with heat for optimal vulcanization.

Abstract: The present disclosure relates to a process for making a seamless tube from a liquid. A mandrel may be provided having a longitudinal axis, an outer surface and a length. A liquid material may be applied to the outer surface of the mandrel by one or more doctor blades, spaced apart from the mandrel outer surface and inclined at an angle ? with respect to the mandrel longitudinal axis, which may be moved along the longitudinal axis of the mandrel while rotating the mandrel around its longitudinal axis. One or a plurality of fingers may overly the mandrel and be positioned upstream of the one or more of blades, relative to the direction of movement of the blades along the longitudinal axis of the mandrel. The liquid material may then be converted to form a seamless tube.

Abstract: A machine and a method for forming composite materials are provided. The machine includes a frame and at least one forming beam attached to the frame, the at least one beam being arranged to align with a mandrel. The forming beam is pivotally segmented into at least two segments to conform to the shape of the mandrel, or alternately is bendable to conform to the shape of the mandrel. The mandrel is receivable within the frame in alignment with the forming beam. An apparatus is also provided to position a composite charge over the mandrel, and to position the mandrel within the frame. A further apparatus is provided to transport the mandrel, and to urge the mandrel toward the forming beam, forming a composite charge.

Abstract: Apparatus for making variously shaped pastry shells includes an annular baking ring supported on a horizontal lower plate to define an upward-facing female die. A gasket is disposed between the baking ring and the plate. An upper plate is positioned above and parallel to the lower plate, and includes a downward-facing male die configured to be inserted concentrically into the upper end of the female die and thereby define a die space having a flat floor and annular, vertical side walls between the dies. An annular collar is disposed concentrically about the male die and resiliently supported on the upper support plate such that, when the two plates are urged toward each other, the collar seals the upper and lower ends of the die space, and a volume of pastry dough disposed in the cavity of the female die is formed into a pastry shell conforming to the die space.

Abstract: Extruding radiused plastic articles with an extruding machine terminating in die defining a path of travel between upstream and downstream ends. The die has an outlet opening extending longitudinally in the direction of the path of travel, the opening oriented so a polymeric material is extruded therefrom in a direction approximately perpendicular to the path of travel through the die. Oppositely rotating rollers of tapered diameters are disposed side by side to receive the extrudate therebetween, the rollers arranged so their longitudinal axes intersect and their smaller diameters are oriented towards the downstream end of the die. Extrudate passing through the opening is characterized by a higher flow rate proximate the upstream end thereof to thereby form a radiused extrusion. The rollers draw the extrudate from the die outlet opening without significantly altering the radiused shape of the fluid plastic material.

Abstract: A date storage master disk and method of making a data storage master disk. The data storage disk master is for use in a data storage disk replication process. The data storage disk molding processes produces replica disks having a surface relief pattern with replica lands and replica grooves. The method includes providing a master substrate. The master substrate is at least partially covered with a layer of photosensitive material. A surface relief pattern having master lands and master grooves is recorded in the data storage disk master, including the steps of exposing and developing the photosensitive material is controlled to form master grooves extending down to a substrate interface between the master substrate and the layer of photosensitive material, such that the width of the master grooves at the substrate interface corresponds to a desired width of the replica lands.

Abstract: An apparatus for placing mold charges into a mold of a compression molding machine includes a carrier, an arm pivotally mounted on the carrier and a mold charge pick-up cup on the arm at a position spaced from the carrier. The arm is pivotal on the carrier between a first position at which the arm is positioned to deposit a mold charge into a mold and a second position at which the mold charge pick-up cup is disposed to transport the mold charge. The carrier preferably is mounted for rotation around an axis. In some embodiments, a cam mechanism is coupled to the arm to pivot the arm as a function of rotation of the carrier. A spring may be coupled between the arm and the carrier for biasing the arm toward one of the first and second positions of the arm. In another embodiment, an actuator is carried by the carrier and coupled to the arm to pivot the arm with respect to the carrier. The arm preferably includes a passage for selective application of air and/or vacuum to the mold charge pick-up cup.

Abstract: A method and apparatus are provided for forming elongated composite structural members with a desired cross-sectional geometry as taken transverse to the length of the member. An apparatus may include a base with a substantially elongated mandrel mounted thereon. One or more rollers configured to at least partially complementarily engage the mandrel are configured to roll over and press one or more plies of composite material onto the mandrel. The mandrel may be disposed on a rotary table and configured to exhibit a curved elongated geometry to form at least partially curved or arcuate elongated members. The present invention enables the formation of elongated structural members from resin impregnated materials while maintaining the materials in a substantially uncured state. The formed members may then be cocured with a skin or other composite structure.

Abstract: An apparatus for hot embossing lithography includes a press mold (20), a substrate (10), a first heating device (40), a second heating device (40?), and a vacuum chamber (32). The press mold has a main body (21) and a number of relief structures (22) extending therefrom. The substrate (10?) is configured for holding a polymer thin film (30) to be pressed. The first heating device (40) is adapted for heating the press mold, while the second heating device (40?) is adapted for heating the polymer thin film on the substrate. The vacuum chamber (32) has an opening (33) through which a vapor (34) can be introduced into the chamber, in order to lower a surface energy of the press mold. The press mold and the substrate are accommodated in the vacuum chamber, and the press mold is aligned with the polymer thin film on the substrate.

Abstract: The present invention is directed to a template that features a control surface extending from a periphery of a mold toward a recessed surface of the template forming an oblique angle between a portion of the control surface disposed proximate to the periphery.

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.

Abstract: The invention can be defined in its most general form as a device for sheet material corrugation by means of bending and can be applied in the devices for production of single curvature folded core used in production of aircraft and craft curvilinear panels. The invention has for its object to broaden the technological capabilities. For that the mandrel is made in the form of a set of alternating rows of plane elements (4, 6, 7) made in the form of trapeziums (4) and isosceles triangles (6, 7) fixed on the flexible material of the base (5) forming thus the gap-pivots between the elements. At the same time the bases of the triangular elements (6, 7) face each other in pairs along the bending lines while said bending lines correspond to the protrusions lines of the core folded structure. The base of the triangular elements (6, 7) is the function of the folded core block curvature radius and the geometrical parameters of the zigzag crimp structure.

Abstract: A method of performing imprint lithography of a surface substrate includes a stamper having a thin lubricant coating thereon to facilitate release of the stamper from the imprinted surface to reduce degradation of image replication. Embodiments of the invention include stampers suitable for use in patterning servo information on magnetic recording media having a lubricant coating of from about 1 nm to about 20 nm.

Abstract: An apparatus for producing a deep-nested embossed product including a first embossing member and a second embossing member. The first embossing member has a plurality of discrete embossing elements disposed in a first non-random pattern. The second embossing member has a plurality of second embossing elements including at least one linear embossing element. The second embossing elements are disposed in a second non-random pattern such the first non-random pattern and the second non-random pattern nest together to a depth of greater than about 0.01 mm.

Abstract: An apparatus for producing a deep-nested embossed product including a first embossing member and a second embossing member. The first embossing member has a plurality of discrete embossing elements disposed in a first non-random pattern. The second embossing member has a plurality of second embossing elements including at least one linear embossing element. The second embossing elements are disposed in a second non-random pattern such the first non-random pattern and the second non-random pattern nest together to a depth of greater than about 0.01 mm.

Abstract: An object of the invention is a method of forming by hot stamping pieces of complex sheeting, composed of a one-piece element comprising several parts of relatively low thickness arranged in different intersecting planes, proceeding from a blank composed of at least one layer of fibers, which have been pre-impregnated with a thermoplastic resin, in which said preheated blank is formed in an assembly composed of a punch and a die. The method includes the steps of a first phase, the part of said blank that is to comprise the bottom or analog of the piece to be obtained is pressed against the bottom of the die, then the second phase, the part or parts of the blank comprising the flanged edge or flanged edges of said piece are pressed against the sides of the die, the work piece that has been obtained in this way then being removed from the jig.

Abstract: The device contains the transformable mandrel (12) made of plane elements (14) pivotedly connected in-between with the use of gas-proof fabric (15,16), the means for preliminary and final mandrel transformation including the flexible vacuum chamber and traverse-pusher (11) with the drive (10), and the mechanism for putting the transformable mandrel into its initial plan state made in the form of two parallel slabs (6, 7) with the drive for their reciprocal travel (9). The means for preliminary mandrel transformation is made in the form of the system of pushers placed in rows on the lower and the upper slabs with individual drives. The perforations in the slabs provide the possibility for the pushers to interact with the transformable mandrel placed between the slabs whereas the mandrel with sheet blank article is put into the vacuum chamber.

Abstract: An aircraft fuselage barrel (10) includes a skin (12) and a shear tie (18). The shear tie (18) resides within and is integrally formed with the skin (12). The shear tie (18) is separate from and configured for frame attachment thereon. A multi-ring system (79) for fuselage barrel formation includes a mold (68) with a ring (50). The ring (50) has width (W2) approximately equal to a separation distance (D) between two adjacent fuselage frames (22) and includes a module (52) that has a circumferential length (L1) that is greater than a circumferential distance between two fuselage longerons (14). A support structure (80) is coupled to and supports the mold (68). A method of forming the aircraft fuselage barrel (10) includes constructing the support structure (80). Rings (86) of the mold (68) are attached to and over the support structure (80). The mold (68) is constructed. Material is laid-up onto the mold (68) to integrally form the one-piece fuselage barrel (10) including a Hat-configured longeron (14).

Abstract: The invention is directed to adjustable length mold assemblies for forming inflatable members and methods for using adjustable length mold assemblies for forming inflatable members, such as, for example, balloons for use with balloon catheters and stent delivery systems. The adjustable length mold assemblies comprise at least two mold pieces adapted to fit together, one mold piece having a surface configured to be slidably received by a bore of the other mold piece, the placement of one piece within the other defining a chamber of variable length which forms the mold. Each adjustable length mold assembly of the present invention is effective to form balloons, where if desired different balloons formed by a single mold may have different lengths. The adjustable length mold assemblies may also comprise a positioner to put a mold piece in a desired position relative to the other, and a locking mechanism to secure a mold piece in a desired position.

Abstract: A plug assist drive assembly for driving plug assists in a thermoforming apparatus includes a single centrally located roller screw assembly enclosed in a housing and driving a third platen mounting the plug assist with a group of guide-drive bars connected to a drive platen which is driven by the roller screw nut. The roller screw assembly is removable by removing screws holding the nut to one hub adapter, the screws accessed through an opening in the housing normally covered with a plate.

Abstract: An object of the present invention is to provide a novel mandrel using a used mandrel, a method of use thereof and a production method thereof. The mandrel of the present invention has an inner layer formed from a thermoplastic resin composition containing an age resister and an outer layer made from a thermoplastic resin which covers the outer circumference of the inner layer. Preferably, the mandrel of the present invention is used for forming a rubber hose and preferably, the inner layer of the mandrel of the present invention is made from a thermoplastic composition obtained by pulverizing a used mandrel for forming a rubber hose.

Abstract: A mold capable of preventing deterioration of the mold even when a material for spherical members is harder than that for the mold, and capable of aligning the center axis between an insert member and a body member thereof with high accuracy even when a pressure of resin filling is applied. The mold has an insert member with a cavity surface, and a body member for supporting the insert member from outside via a plurality of spherical members. Tubular liners harder than the spherical members are provided between the body member and the spherical members and between the insert member and the spherical members.

Abstract: An apparatus and methods for forming a composite part are provided. A method for forming a composite part may include placing initial composite material on a base tool, placing a tooling mandrel on the composite material, placing additional composite material over the tooling mandrel, covering at least a portion of the composite material that overlays the tooling mandrel with a composite forming tool, heating the composite material to at least partially cure the composite material, and permitting a first portion of the composite forming tool to change size during the heating of the composite material to a greater degree than a second portion of the composite forming tool. In this regard, the second portion of the composite forming tool is closer to the base tool than the first portion of the composite forming tool. A composite forming tool is also provided that permits differential expansion of different portions of the tool.

Abstract: In the case of a thermoforming system, it is provided, for the purpose of changing over the moulds (11, 12) in a station (1) of this system, that one (4) of the two transporting devices (3, 4), for transporting the sheet (7) from one station to the other, can be displaced in the direction of the other transporting device (3), transversely to the conveying direction, in order to create space on one side of the lifting tables (9, 10) so that it is possible for the mould block (11, 12) to be moved out of the station onto a mould-changing arm (13) and, from there, onto a mould-changing carriage (15).

Abstract: An aircraft stringer lay-up assembly is provided comprising a contoured curing block and a first mandrel element positioned thereon. The first mandrel assembly includes a first bar assembly having a plurality of rigidity reducing first slots formed along a first mandrel length. The plurality of rigidity reducing first slots protruding partially through a first mandrel depth of the first mandrel element to allow the first bar assembly to conform to the contoured curing block. A composite ply assembly is laid up onto the first mandrel element and cured while conformed to said contoured curing block such that a contoured composite stringer element is generated.

Abstract: A system and method for controlling curl in multi-layer webs. The method can include providing a coated web, curing the coating to form a multi-layer web, and stretching the web during curing of the coating. Some coatings shrink at least partially when cured such that curing the coating induces a strain in the multi-layer web. Stretching the web occurs during curing to induce an opposing strain that at least partially counteracts the strain induced by curing to form a multi-layer web having a desired curvature. The system can include a curing section configured to cure the coating, and can further include a web stretching section, which can be located proximate the curing section and can be substantially coincident with the curing section, such that the web is stretched while the coating is cured.

Abstract: A molding apparatus for patterning a workpiece includes a mold having a pattern to be transferred to the workpiece, with the pattern including recesses, a first support member for supporting the mold, and a second support member, arranged opposite to the first support member, for supporting the workpiece. A pressing mechanism brings the first and second support members close to each other and presses the mold and the workpiece together so as to transfer, to the workpiece, the pattern on the mold. Recessed portions are provided on at least one of a surface of the mold on the first support member side, a region of the first support member, and a region of the second support member. The recessed portions correspond to recesses in the pattern of the mold.

Abstract: The present invention is directed to a template having a body including a surface with first and second regions. The first region has first wetting characteristics for a given material and the second region has second wetting characteristics for the given material. The first wetting characteristics differ from the second wetting characteristics. Specifically, the first region is formed from a surface treatment layer with a first surface energy to provide the first wetting characteristics. The second region is exposed portions of the body, typically quartz of fused silica, having a second surface energy associated therewith. The second surface energy is greater than the first surface energy to provide the second region with the second wetting characteristics.

Abstract: A method of performing imprint lithography of a surface substrate includes a stamper having a thin lubricant coating thereon to facilitate release of the stamper from the imprinted surface to reduce degradation of image replication. Embodiments of the invention include stampers suitable for use in patterning servo information on magnetic recording media having a lubricant coating of from about 1 nm to about 20 nm.

Abstract: An apparatus for forming elongated composite structural members with a desired cross-sectional geometry as taken transverse to the length of the member. The apparatus may include a base with a substantially elongated mandrel mounted thereon. One or more rollers configured to at least partially complementarily engage the mandrel are configured to roll over and press a plurality of plies of composite material onto the mandrel. The rollers may be configured to form intermediate structures which partially conform to the geometry of the mandrel prior to forming the final structure, which substantially completely conforms to the geometry of the mandrel. The rollers serve to both form and debulk the structure. The present invention enables the formation of elongated structural members from resin-impregnated materials while maintaining the materials in a substantially uncured state. The formed members may then be cocured with a skin or other composite structure.

Abstract: An apparatus and method for forming tow-based absorbent structures having a single casing sheet are disclosed. The apparatus has a tow supply mechanism for providing tow material, a particulate matter supply mechanism for providing particulate matter, and a casing sheet supply mechanism for providing casing sheet material. The apparatus also has a vacuum draw roll having a foraminous center surface that has a width defined by a first edge and a second edge and is rotatable about a first axis. The vacuum draw roll is positioned to receive the tow material, the particulate matter and the casing sheet material to form a open core composite supply. The apparatus also has one or more angled surfaces positioned to create one or more obtuse angles in the open core composite supply, and one or more folders to further fold the one or more obtuse angles in the open core composite supply to form a folded core composite supply.

Abstract: An apparatus and process for continuously and endlessly vulcanizing a hose is disclosed and claimed. Pressurized air or other gas is intermittently supplied through a woven jacket, a mandrel, a check valve and into the interior of an extruded rubber hose. The hose is sealed as it is pulled over the mandrel. Pinch rollers seal the other end of the hose. One or more non-contact heaters vulcanize the hose from outside-in. Pressurizing the inside of the hose maintains proper diametrical dimensions of the hose.

Abstract: A sheet material pressing machine for pressing a sheet material into a formed article may include a first die unit that can be opened and closed and a second die unit that can be opened and closed. The first and second die units are arranged and constructed such that closing operation of the first die unit and opening operation of the second die unit, or vice versa, can alternately occur.

Abstract: The invention relates to a matrix suitable for use in the replication of a plastic element having a positive microstructure, comprising a first wear-resistant layer that is supported by a carrier element, wherein the matrix comprises a heating means for supplying electrical heat energy through the wear-resistant layer or carrier element. The invention further relates to a plastic element producing machine and a method for the manufacture of a plastic element having a surface with a positive microstructure.

Abstract: An embedment device for use in a structural panel production line wherein a slurry is transported on a moving carrier relative to a support frame, and chopped fibers are deposited upon the slurry, includes a first elongate shaft secured to the support frame and having a first plurality of axially spaced disks, a second elongate shaft secured to the support frame and having a second plurality of axially spaced disks, the first shaft being disposed relative to the second shaft so that the disks intermesh with each other. The intermeshing relationship enhances embedment of the fibers into the slurry and also prevents clogging of the device by prematurely set slurry particles.

Abstract: A tube bending fixture having a frame. An upper and lower tube support are both pivotally mounted to the frame between a first and second pivotal position. A bar is slidably mounted to the upper tube support and movable between an extended and a retracted position. At least one lower mandrel is mounted to the lower tube support and is dimensioned to fit within one end of a tube to be bent. At least one upper mandrel is mounted to the slidable bar, and the upper and lower mandrels are aligned with each other when the upper and lower tube supports are in their first pivotal position. The upper mandrel is dimensioned to fit within the second end of the tube to be bent when the bar is in its extended position. A former is secured to the frame and includes a channel which engages a midportion of the tube and conforms to the desired shape of the tube when the first and second tube supports are in their second pivotal position.

Abstract: A substrate imprint tool is provided with a light transparent base and a light blocking distal end that is coupled to the light transparent base.

Abstract: The present invention is directed toward a system to vary dimensions of a template in order to attenuate if not prevent distortions in an underlying pattern formed by the template. To that end, the system features a compression device that includes a pair of spaced-apart contact members to compress a perimeter surface of the template between the pair of spaced-apart contact members. The compression device includes first and second bodies, each has a contact member and an actuator arm. One of the actuator arms is coupled to the first body to reciprocate about an axis in response to variations of a volume of a bladder disposed adjacent to the actuator arm. In this manner, the distance between the two contact members may be varied.

Abstract: A connector element for connecting frame parts at a joint location in a bicycle frame is made of a single part of structural fiber based material, typically carbon fiber material, after reticulation in a mold exploiting the expansion of a core on which windings of fiber fabric material are provided, to obtain the application of a uniform radial pressure on the layers of fiber based material. In one embodiment, the connector element defines a bicycle bottom bracket and tubular extensions extending therefrom for connection to elements of the bicycle frame.

Abstract: The invention is concerned with a compression molding device (1) with a tool (3) generating at least a part of the work-piece geometry. At least one pressure measuring means (5) and/or at least one pressure space (4) is located directly below the work-piece associated surface (3.3) of the tool (3). Besides this, the work piece (3) selectively exhibits at least one first part (3.1) which is a tool template generating the shape of the work piece and a second part (3.2) forming the base body, wherein a measuring strip (6) is provided between the tool template (3.1) and the base body (3.2). As an optional refinement, the measuring strip (6) is an elastic intermediate layer with a smaller modulus of elasticity than the base body (3.2).

Abstract: There is provided an apparatus and method for consolidation joining a thermoplastic preform to form a duct. The apparatus includes first and second longitudinally extending support structures. The first support structure at least partially defines a cavity for supporting the preform in a desired configuration of the duct. The second support structure extends in the cavity such that the preform can be supported between the first and second support structures. The second support structures can include an elastomeric device that is configured to adjust radially and urge the interface of the preform against the first support structure. A heater is configured to heat an interface of the preform to above a glass transition temperature. The resulting duct is has a longitudinal consolidation joint and defines a passage.

Abstract: A customizable skirt-forming member is disclosed, for use in high stress acrylic tub formation operations. The member generally has a rigid forming wall, at least one adjustable wing hingeably associated with the forming wall, and means for altering the pitch of the at least one wing, relative to the sidewall, so as to simultaneously alter a hinge angle therebetween. The member allows for customized, angled formed front tubs to be formed, while ensuring that the stresses of system operation do not alter the intended angles. A toggle-nut structure is additionally disclosed, which ensures the maintenance of the relative positions of the angled walls of the skirt-forming member.