Abstract: A thermal protection system suitable as a heat shield for a space vehicle includes a flexible insulation mat that is adhesively bonded onto the outer skin of the space vehicle, a cover layer made of at least one ply of a ceramic fiber composite material secured onto the insulation mat, and a coating of an inorganic material applied onto an outer surface of the ceramic cover layer. The cover layer is secured to the insulation mat by adhesive bonding, stitching with ceramic threads or the like, or by a snap fastener button connection. The ceramic fiber composite materials of the cover layer include inorganic fibers which are preferably oxides, carbides or mixtures thereof embedded in a matrix of the same compositional components, whereby the components can be selected appropriately depending on the requirements of the particular application.

Abstract: The invention relates to inflatable fabrics which comprise two separated and distinct fabric layers in discrete areas of such fabrics as well as connecting seam-producing materials to which such fabric layers are simultaneously attached. The resultant inflatable fabric composite thus includes inflatable areas separated, at least partially, by seamed barrier areas. This configuration will form “pillowed” structures within the target fabric upon inflation. Such connecting seam-producing materials are incorporated within the two-layer structure as peel seams in relation with the individual fabric layers. Upon inflation, the seams then act as shear seams which greatly increases the overall strength of the two-layer inflatable fabric. These shear seams thus provide a relatively effective manner of reducing air permeability within the entire fabric article. Such a fabric may be utilized in numerous and various applications wherein fabric inflation is desired or necessary.

Abstract: A courier expressable cargo quilt having an elongated, substantially rectangular body comprising an insulative material including a plurality of panels substantially foldably connected, defining an accordian-like structure, the accordian-like structure having an unfolded position adapted to facilitate placement of the body substantially over a tmperature sensative load by unfolding the accordian-like structure and a folded position adapted to provide a courier-expressable cargo quilt; and an exterior cover structure adapted to at least partially enclose the accordian-like structure.

Abstract: Reactive hot melt polyurethane adhesives are useful in the graphic arts area, and in particular, for bookbinding applications such as casemaking, casing-in, gluing-off or thread-securing, facing, slip cases, lining-up, tightbacking, and bonding sides and joints; and for puzzle and gameboard lamination.

Abstract: Lightweight, non-woven loop products for hook-and-loop fastening are disclosed, as are methods for making them and end products employing them. The products are non-woven webs of entangled fibers of substantial tenacity, the fibers forming both a sheet-form web body and hook-engageable, free-standing loops extending from the web body. The product is stretched and stabilized to produce spaced-apart loop clusters extending from a very thin web of taut fibers. In some embodiments, the fibers include low denier fibers and/or bicomponent fibers.

Abstract: A stitched laminate, in which plural sheets respectively having plural tow-like carbon fibers arranged in parallel to each other are laminated, with the orienting directions of the carbon fiber yarns of the respective sheets kept at different angles against a reference direction, and are stitched integrally using stitching threads. The fineness of each of the carbon fiber yarns is in a range of 1,200 to 17,000 Tex, and the pitch of the arranged carbon fibers yarns is in the range of 8 to 60 mm. In the sheets, the arranged carbon fiber yarns are widened in yarn width to ensure that no gap substantially exists between the respectively adjacent carbon fiber yarns. The plural carbon fiber yarns supplied to form sheets are respectively brought into contact with plural rollers, to be bent and widened in yarn width.

Abstract: In a belt-shaped body where plural coupling elements are fixed along a periphery of a long tape main body, when a width of the tape main body is W, dimension from a first coupling position center of said coupling elements up to an end face in the length direction of the tape main body near said is a′ and the number of tape windings except top/bottom faces thereof is N, a length L′ in the length direction of the tape main body is obtained according to the following expression (I): 1 L ′ = ( 1 + α 100 ) [ K ⁢ { a ′ βcos ⁡ ( tan - 1 ⁢ ωβ a ′ ) - AT } - 2 ⁢ NBW ]

Abstract: In a preferred embodiment, the present invention comprises a layer having carpeted upper surface and/or other rubber-like padding material covered by a translucent, elastomeric sheet. The upper elastomeric layer may have downwardly depending projections that engage the carpeted upper surface of the inner padding layer, thereby reducing the likelihood of the upper elastomeric layer from slipping relative to the inner padding layer. The upper elastomeric layer is sewn or otherwise affixed to the carpeted surface to prevent slipping and creasing of the upper elastomeric layer relative to the padding during use. In addition, in a preferred embodiment for use on carpeted surfaces, the lower elastomeric layer may have downwardly depending projections that engage in the underlying carpet surface to reduce slipping of the device relative to the underlying surface. An overcovering material may be provided to further protect the upper elastomeric layer from excessive soiling.

Abstract: A laminate for bedding, padding upholstering and like applications by feeding an indeterminate length of a first material along a predetermined first path of travel from a source of the first material to a downstream assembly area. Feeding an indeterminate length of second material along a predetermined second path of travel from a source of the second material to the downstream assembly area. Depositing a multiplicity of substantially yieldable cushioning materials upon an upper surface of one of the first and second indeterminate lengths of material during the feeding thereof between the respective sources and the assembly area. Thereafter, sandwiching the cushioning materials between the indeterminate lengths of first and second materials to form a laminate therefrom, and rolling the laminate into a roll. The cushioning materials are foam latex and/or down and the first and second lengths of material are polyester fiber material and/or convoluted foam.

Abstract: The present invention 10 discloses a high temperature insulation blanket for an exhaust system of an internal combustion engine. The blanket 10 can be selectively manufactured to encompass any engine parts deemed desirable by the user. All sides of the insulative blanket 10 have a high temperature abrasive resistant outer shell material 24 fixedly attached thereto. The high temperature insulative blanket is comprised of a ceramic core 22 having an interior engine engaging layer and an exterior atmospheric air layer. The interior layer is comprised of an inconel or monel mesh material 20 that provides a spacing between the engine components and the ceramic fill 22. An inconel or monel liner 32 prevents any engine fluids from wicking into the ceramic fill 22. The exterior layer 24 is comprised of a Teflon layer that is substantially impervious to petroleum based products and solvents. The present invention 10 provides three means of closure for the insulative blanket.

Abstract: Prefabricated composite detail parts use precured strips that include Z-pin reinforcement along the bond line. Each strip has Z-pin stubble protruding from opposed faces so that the pins are embedded into the detail parts when the joint forms.

Abstract: A fabric tape structure is formed of a fabric tape and an elastic strip attached to the surface of the fabric tape. The elastic strip is provided with words, marks, and patterns, which are printed thereon. The elastic strip is coated with a fluorescent of light-reflecting substance.

Abstract: A method is disclosed for creating a design that appears to float in the face of a piece of material. A piece of fusible material is placed on top of a first piece of material. The fusible material is coated with an adhesive. The non-adhesive side of the fusible material is in contact with the face side of the first piece of material. The fusible material is sewn to the first piece of material. The stitches define the periphery of an unbroken design. The fusible material is trimmed outside the periphery of the unbroken design. Next, the fusible material and the fabric are trimmed inside the unbroken design to create an aperture. The fusible material is pulled through the aperture so that the adhesive is substantially interposed between fusible material the reverse side of the first piece of material. The fusible material is then fused to the reverse side of the first piece of material. A second piece of material is placed on the reverse side of the piece of fabric to cover the aperture.

Abstract: The present invention is a component having a synthetic wood layer that is secured to a foamed polymer layer. The foamed polymer layer is comprised of a polymer selected from the group consisting of high density polyethylene, polypropylene, polyvinyl chloride, low density polyethylene, chlorinated polyvinyl chloride, acrylonitrile butadiene styrene, ethyl-vinyl acetate, and polystyrene. The component can be used for a variety of different purposes such as fencing, furniture, cabinets, storage devices, lawn edging, flower boxes, flooring, roofing, wall covering, building siding, basement flooring, basement wall covering, interior and exterior decorative house moldings, crown moldings, chair rails, picture frames, porch decks, deck railings, window moldings, window components, door components, door moldings, various other lawn and garden uses, various other below grade uses, and various other indoor and outdoor uses.

Abstract: A composite material-stiffened panel has a skin obtained by molding a fiber-reinforced resin composite material into a flat skin, stiffeners arranged in rows on one surface of the skin, and a fiber-reinforced resin-composite material stitched on the skin covering the stiffeners. The composite material-stiffened panel can be manufactured as follows: A first fabric material is placed on a tool having a panel-shaped surface. Stiffeners are placed on the first fabric materials. A second fabric material is placed on the stiffeners to cover at least some of the stiffeners. The second fabric materials are reformed to match the shape of the stiffeners. The reformed second fabric material is stitched on the first fabric material along edge of the stiffeners. All the materials are covered with a bagging film for vacuum. Resin is infiltrated into the fabric materials by a RTM or a RFI method. The infiltrated resin is heated to be hardened.

Abstract: The invention relates to a cover for hot outdoor grills. It comprises a cotton flannel material on which an aluminized vinyl is coated on the surface. This material is resistant to excessive heat and can also repel water.

Abstract: An improved stitchbonded nonwoven fabric having repeating patterns of stitches in a fibrous layer is prepared with a stitching thread that consists essentially of fiber of partially molecularly oriented synthetic organic polymer. The fabric can be stretched, shrunken, and/or heat set and is particularly suited for thermoforming operations.

Abstract: Low density semifinished product for manufacturing buoyant products, comprising a plurality of layers of closed-cell expanded material, having a specific gravity lower than that of water, the said layers being flexible and elastic and being joined together by quilting spaced so as to define between them pockets of air, characterised in that the said quilting is preferably distributed in closed patterns.

Abstract: A flat composite fabric is provided by incorporating wire made of memory metal, or made of an alloy possessing shape memory properties into a flat fabric. By means of appropriate heating and cooling, e. g. electric heating, the composite fabric is contracted and released thereby providing a massaging effect.

Abstract: A belt for supporting strips of deformable material includes a flexible central band onto which one or more strips of the deformable material are placed, wherein variable-configuration spacing elements are arranged along edges of the central band. The spacing elements may be air chambers. An apparatus for using the belt, a method for feeding a strip of deformable material, and a method for storing a strip of deformable material on a storage coil are also disclosed.

Abstract: A papermaking belt comprises a reinforcing element and a resinous framework joined together. The resinous framework is formed by a plurality of resinous beads which mutually contact or cross-over. Super-knuckles extending outwardly from the reinforcing element are formed at points of contact. A preferred continuous process for making the belt comprises extruding, in a pre-selected pattern, a plurality of beads of a resinous material onto the forming surface thereby forming the resinous framework thereon, joining the resinous framework and the reinforcing element together, and then solidifying the resinous framework. The resinous material may comprise at least two chemically-active materials capable of cross-linking upon contact.

Abstract: A new and improved covering apparatus is disclosed which would allow a user to absorb moisture, dirt, and other substances readily. The covering apparatus would comprise two layers, a first layer and a second layer, with the first layer being fabricated from an absorbent material, such as terry cloth and a second layer being fabricated from a waterproof material, such as vinyl plastic backing. The two layers would be bonded or sewn together.

Abstract: An airbag having at least two composite layers of fabric R.F. welded around the periphery thereof to form the bag and, which, when R.F. welded has excellent seam strength and a specific inflation strength less than 1.2.

Abstract: A reinforcing web constituted by substantially parallel and spaced-apart warp threads and by pairs of reinforcing threads, each shaped in the form of successive half-loops alternating in a weft direction. The successive half-loops of the reinforcing threads in each pair extend in opposite directions, and the pairs of threads are spaced apart from one another in such manner that the half-loops of the threads corresponding to two successive pairs overlap and together define closed loops which are set by means of flexible binding stitches formed in the overlap zones between the two half-loops and the warp threads. At least some of the reinforcing threads are constituted by metal tows. The reinforcing web is suitable for application to the seats of public transport vehicles.

Abstract: A nonwoven fabric protective cover article disclosed comprises a top surface, a bottom surface, at least one edge, and at least one weight joined thereto. The nonwoven fabric of the protective cover article is hydrophobic and has a basis weight from between about 0.15 osy to about 8.0 osy, an air permeability from about 60 ft3/min/ft2 to about 110 ft3/min/ft2, and stain resistance from about 4 to about 5 for blueberry, instant coffee, gravy, and wine.

Abstract: The insulating cover comprises a gas and water impermeable first foil (13) which defines a first circumferential outer rim, a gas and water impermeable second foil (26) substantially coextensive with said first foil (13) and defining a second circumferential outer rim. The first (13) and second foil (26) are joined together at the first and second outer circumferential rims of the first (13) and second outer circumferential rims of the first (13) and second foils (26), to define an enclosure between the first (13) and second (26) foils. A body of insulating material (24) is inserted in the enclosure. A plurality of supporting tubular elements (20) in co-planar relationship with said first (13) and second foil (26) provide a stiffness of the insulating cover (15) in axial direction of the plurality of supporting tubular elements (20) and flexibility of the insulating cover (15) in a direction perpendicular to the axial direction.

Abstract: A vehicle interior hand grip material for mounting on an existing gear shift lever arm, on a portion of a steering wheel and other items operated by hand inside a vehicle. The hand grip material includes a plurality of flexible “string like” elastomeric members extending outwardly from an attachment member. The attachment member may be a thin wire wrapped around a portion of the elastomeric members and tightened thereon. Also, the attachment member may be a liner with one end of the elastomeric members attached to the liner. The wire attachment member can be secured around a gear shift threaded housing threaded on an end of the vehicle's gear shift lever arm. Also, the wire attachment member can be attached to other hand operated items inside the vehicle. Further, the steering wheel liner attachment member can be placed around a portion of the vehicle's steering wheel.

Abstract: A method of manufacturing a laminate particularly adapted for bedding, padding upholstering and like applications by feeding an indeterminate length of a first material along a predetermined first path of travel from a source of the first material to a downstream assembly area. Feeding an indeterminate length of second material along a predetermined second path of travel from a source of the second material to the downstream assembly area. Depositing a multiplicity of substantially yieldable cushioning materials upon an upper surface of one of the first and second indeterminate lengths of material during the feeding thereof between the respective sources and the assembly area. Thereafter, sandwiching the cushioning materials between the indeterminate lengths of first and second materials to form a laminate therefrom, and rolling the laminate into a roll. The cushioning materials are foam latex and/or down and the first and second lengths of material are polyester fiber material and/or convoluted foam.

Abstract: To make an annular fiber structure, a strip-shaped fabric (50), is used which is made up of two superposed unidirectional sheets, with the directions of the sheets forming opposite angles relative to the longitudinal direction of the strip, the two sheets being bonded together so as to form deformable elementary meshes, the fabric being wound while being deformed so as to transform it into a flat helix, the elementary meshes deforming in such a manner that variation in mass per unit area between the inside and outside diameters of the turns remains small, and the flat turns are pressed against one another.

Abstract: A protective armor construction which reduces blunt action trauma and provides excellent penetration resistance, includes multiple layers arranged in serial relation between the front and back. These layers include a first plurality of layers of a penetration resistant material fabricated of high strength, e.g., aramid, fibers. These layers are secured together at the peripheral edge, e.g., by sewing, and are backed by a first plurality of backing layers of a thermoplastic polyester extrudable in sheet form, such as polyethyleneterephalate. Next is a further plurality of layers of a penetration resistant material fabricated of high strength fibers. These layers are disposed in serially contacting, unsecured relation so that the layers can individually flex and expand in response to bullet impact. These layers are backed by a further plurality of layers of an extrudable thermoplastic material.

Abstract: Omnidirectional bellows for reciprocal displacement is provided which, by preventing disproportional stretching or sagging in the midsection of bellows from occurring under any circumstances of positional alteration or intensive vibrations, allows normal reciprocal displacement operation to be continued. The omnidirectional bellows comprises, in a combination of a guide-rail with the bellows formed of multiple concaved sheets of same size and same shape communicating each with other for covering flexibly longitudinally along with one side of the guide-rail, a contour along with each inner border of said multiple concaved sheets being formed to follow cross-sectional profile in a direction perpendicular to the longitudinal direction of the guide-rail, and at least said each inner border being surface treated with material having small slipping resistance and large friction strength.

Abstract: An oil or solvent absorber in the shape of a sock or pillow made of needle punched polypropylene, melt blown polypropylene, or textiles such as cotton or cotton blends, either by stuffing scraps of material into a cover or rolling sheets and then covering them with a cover or by making a stack of layers of material and then covering the stack of layers with one of these materials.

Abstract: The invention relates to inflatable fabrics which comprise two separated and distinct fabric layers in discrete areas of such fabrics as well as C-shaped seam-producing materials to which such fabric layers are attached. The resultant inflatable fabric composite this includes inflatable areas separated, at least partially, by seamed barrier areas. This configuration will form “pillowed” structures within the target fabric upon inflation. Such seam-producing materials are incorporated within the two-layer structure as C-shaped peel seams in relation with the individual fabric layers. Upon inflation, the seams then act as shear seams which greatly increases the overall strength of the two-layer inflatable fabric. These shear seams thus provide a relatively effective manner of reducing air permeability within the entire fabric article. Such a fabric may be utilized in numerous and various applications wherein fabric inflation is desired or necessary.

Abstract: A lightweight, high-strength composite fabric suitable for use in carpet backing, roofing and membranes and other products which employ rugged fabrics. The composite fabric comprises a layer of nonwoven material disposed between a layer of low shrinkage warp strands and a layer of low shrinkage weft strands. The layers are stitched or knitted together and the resultant fabric may be coated with a resin or sizing to prevent slippage between the several layers of the fabric and impart a measure of stiffness to the fabric. The fabric may be manufactured in sheet or, more preferably, roll form and may be coated with materials suitable for desired end applications, e.g., bituminous material whereby the fabric may function as a ready-to-use roofing membrane or other high-strength fabric product.

Abstract: A protective cover for a motor vehicle conventional floor mat comprising a removable fabric protectively enclosing the top side of the mat. An elastic strip integral with the inner rim of the cover removably engages the cover to the underside of the floor mat. The conventional floor mat has a mat irregular peripheral edge and the cover edge is custom fitted to the mat irregular peripheral edge. A cover shape-retaining element integral with the cover side edge keeps the conforming relationship of the cover side edge with the irregular peripheral edge of the floor mat. An elastic strip unitary with the cover inner rim allows the cover to be disengaged from the floor mat by stretching the elastic strip to a biased mode. The cover is preferably made of a polyester pile fabric that generally matches the fabric used in motor vehicles. A waterproof layer is preferably attached to the interior surface of the cover.

Abstract: A package of a continuous strip of material includes a plurality of parallel side by side stacks each containing a length of the strip which is folded back and forth such that each folded portion of the stack is folded relative to the next portion about a line transverse to the strip and such that the side edges of the strip portions are aligned. The strip of material includes a splice defined by the two ends of the strip. The two ends of the strip are held together by yarn stitches passing through and bridging the strip ends.

Abstract: There are described a dimensionally stable laminate whose surfaces are formed by spunbonded webs and comprising at least two layers of spunbonded and at least one laid layer of reinforcing yarn, the laid layer or layers each being disposed between two layers of spunbonded and having a thread density of from 0.5 to 3 threads/cm, spunbonded and laid layers having been joined together by needling at about 20-70 stitches/cm2, a process for manufacturing this laminate, and its use for manufacturing roofing sheets and roof sealing sheets.

Abstract: An interactive thermal insulating system of the present invention includes at least three layers. The first layer is a high density layer comprising a substrate is coated with a polymer binder in which a plurality of microspheres containing a phase change material are dispersed. The second layer is a low density fibrous mesh in which individual fibers contain a plurality of microspheres containing a phase change material dispersed therein. A third layer is a flexible substrate. The fibrous mesh is sandwiched between the coated layer and the third layer. The layers are bonded together by stitching at regular intervals, lamination, or other methods of connection. Most preferably, the phase change materials contained in the microspheres include paraffinic hydrocarbons.

Abstract: Fabrics are used as integral elements of electrical circuitry—to facilitate control over the operation of external components connected thereto, to serve as substrates onto which electrical components are connected, or as the electrical components themselves. In one aspect, selective, anisotropic electrical conductivity is achieved using conductive fibers running along one weave direction and non-conductive fibers running along the opposite direction. The conductive fibers, which may be continuous or arranged in lanes, serve as electrical conduits capable of carrying data signals and/or power, and may be connected, for example, to electrical components soldered directly onto the fabric. In a second aspect, passive electrical components are integrated directly textiles using threads having selected electrical properties.

Abstract: A protector for a front fender of a vehicle that includes a first layer of material for facing the front fender, a second layer of material attached to the first layer of material for facing away from the front fender, apparatus for maintaining the protector on the front fender, and an open topped transparent pocket disposed on the second layer of material for holding papers pertaining to the vehicle. The apparatus includes a pocket that is slender, elongated, and extends along the length of an upper terminal edge of the first layer of material for depending inwardly of the front fender of the vehicle. The pocket is divided into a long central portion, and a pair of short terminal portions that are shorter than and straddle the long central portion of the pocket. The long central portion is filled with sand for weight in maintaining the protector on the front fender, while the pair of short terminal portions are empty of the sand and lie flat for not catching on the hood hinges of the vehicle.

Abstract: Reactive hot melt polyurethane adhesives are useful in the graphic arts area, and in particular, for bookbinding applications such as casemaking, casing-in, gluing-off or thread-securing, facing, slip cases, lining-up, tightbacking, and bonding sides and joints; and for puzzle and gameboard lamination.

Abstract: A courier expressable cargo quilt having an elongated, substantially rectangular body comprising an insulative material including a plurality of panels substantially foldably connected, defining an accordian-like structure, the accordian-like structure having an unfolded position adapted to facilitate placement of the body substantially over a temperature sensitive load by unfolding the accordian-like structure and a folded position adapted to provide a courier-expressable cargo quilt; and an exterior cover structure adapted to at least partially enclose the accordian-like structure.

Abstract: A stitch-reinforced sandwich panel with improved flatwise tensile strength, improved skin to core peel strength, and substantially reduced damage propagation from impact includes a relatively non-compressible foam core, a dry reinforcing layer of fibers placed on each of the opposite faces of the foam core; and high strength thread stitched with a high density of stitches over the entire panel through each of the reinforcing layers and the foam core. The skins are then impregnated with a resin system to complete the structure.

Abstract: A washable cover for mattresses and like objects, that is made from textile material and includes a water vapor permeable, allergen- and waterproof barrier layer, and an outer material. The cover includes at least one additional textile fabric and a voluminous batting at least 3 mm thick. The batting is arranged between the outer material and additional textile fabric. The outer material, batting, and additional textile fabric are joined together at least pointwise by threads. The barrier layer is laminated onto the additional textile fabric at least pointwise after the latter is joined to the outer material and batting.

Abstract: A plastering layer (2) of plastics material, having attached thereto a net reinforcing material (6) to be embedded in or underneath a plaster layer (12), in particular a plaster layer (12) on a thermal insulation (16) of a building wall (26), wherein said reinforcing material (6) is connected to said plastering fillet (2) by means of at least one plastics strand (8), with said reinforcing material (6) having been interposed between plastering fillet (2) and plastics strand (8) when the connection was made, and with a material-uniting connection being established between plastering fillet (2) and plastics strand (8).

Abstract: A laminated fibrous structure comprising at least two fibrous sheets and a method for manufacturing same are provided. At least one, and preferably two, of the fibrous sheets may be embossed. The sheets are movably joined together in a face-to-face relationship to form a laminated structure such that the sheets are able to move relative each other during the use of the laminated structure by a consumer, without tearing or separation of any one of the sheets comprising the laminated structure. The sheets comprising the laminated structure may be movably joined by using a bonding material, by mechanically engaging upstanding fibers created on the interfacing surfaces of the sheets, or by a combination of the bonding material and engaging the upstanding fibers.

Abstract: A tailored structural member that is designed to generate a yield-type response, with applicability to the arrest of a moving body. The structural member comprises a primary load path connected in parallel to a longer secondary load path at a pair of common nodes. The primary load path is designed to fail at a lower load than that required to fail the secondary load path when subjected to a tensile force. As a result of the load redistribution achieved through the use of the redundant paths provided by the primary and secondary load paths, the structural member dissipates more kinetic energy from the moving body within a given set of displacement and deceleration force constraints than is possible using a conventional, uniform cross-section member.

Abstract: A synthetic magnetodielectric composite material for absorbing electromagnetic radiation has a sheet of fabric having first and second surfaces. The fabric is formed of an insulating material. Magnetically permeable thread is disposed within the fabric. The magnetically permeable thread comprises a material having a permeability substantially greater than the permeability of free space. The fabric is impregnated with resin. The magnetically permeable thread is configured to provide predetermined permittivity and permeability within a selected frequency range, so as to provide desired absorption/transmission of electromagnetic radiation.

Abstract: Reinforcement preforms and methods for making same for use in fiber-reinforced composite materials structures are disclosed, in which the reinforcement preforms comprise first and second reinforcement preform elements which include strength reinforcement fibers that are in desired directional orientation. The first element has a cross-fiber surface which extends transverse of its constituent strength reinforcement fibers and is in contacting juxtaposition to a selected surface region of the second element, forming an abutment therebetween. Abutment strength reinforcing fibers, which may optionally be introduced in situ by a continuum of fibers, such as a yarn or thread, extend through at least a portion of said second element and its said selected surface region, the abutment, said cross-fiber edge surface, and into the first element substantially in the direction of orientation to its constituent strength fibers to which its cross-fiber surface is transverse.

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.