Abstract:
Apparatus's and methods of stretch-forming pre-preg material are provided. In one example embodiment a variable material stretch forming apparatus comprises a stretch-forming assembly configured to stretch-form at least one section along a width of a sheet of pre-preg material to a longer length than at least one other section along the width of the sheet of pre-preg material before the sheet of pre-preg material is applied to a tool.
Abstract:
A method for determining the quality of dispersion of glass fibers in a thermoplastic resin preform layer compares the mean characteristic length of the glass fiber bundles in the preform layer to a predetermined value indicative of dispersion of the glass fibers. The thermoplastic resin preform layer characterized by this method comprises a plurality of individual glass fibers and some degree of undispersed glass fiber bundles intimately mixed with a plurality of discrete thermoplastic fibers. The glass fibers are introduced to the mixture having a length of about 1 cm. to about 8 cm. After mixing, some of the glass fiber bundles break up, and some residual glass fiber bundles remain. A preform layer which has acceptable dispersion has residual glass fiber bundles having a mean apparent length of less about 1.365 mm.
Abstract:
A fixing roller for use in the fixing stage of a fixing apparatus such as a copying machine provided with multiple rubber and/or fabric layers of certain thicknesses and hardnesses surrounding a core member to improve the copying characteristics of the roller.
Abstract:
A fiber-reinforced composite vehicle wheel, and a method and apparatus for construction thereof. The wheel comprises a disc portion having reinforcing fibers in substantially random orientation disposed predominantly in planes perpendicular to the wheel axis, and a rim portion having directional first reinforcing fibers substantially parallel to each other and oriented circumferentially of or substantially parallel to the wheel axis, or both, and second reinforcing fibers which are substantially randomly oriented circumferentially of the wheel axis. The method includes formation of separate rim and disc charges from sheet molding plastic resin compound and compression molding of the charges to form an integral composite rim and disc structure of essentially homogeneous resin reinforced by the fibers. An apparatus for molding the wheel features radially movable rim mold sections and axially reciprocable disc mold sections all having mold surface contours for forming a molded composite wheel of desired configuration.
Abstract:
For a cylindrical sodium sulphur cell, a cathode electrode structure is provided with improved electronic conductivity in the radial direction, compared with other directions, by forming a block of fibre material, e.g. graphite fibres, with the fibres aligned in one direction, slicing the block to form a sheet with fibres normal to the plane of the sheet, moulding the sheet and impregnating it with cathodic reactant in a heated mould having a plurality of ribs, to form a plurality of trapezoidal segments with the fibres normal to the planes of the parallel surfaces of the trapezoids, cooling the mould so that the impregnant is solidified and then forming the trapezoids into an annular structure. Preferably the mould is such that thin webs are left joining adjacent trapezoidal sections along parallel edges of the wider of the two parallel faces so that the webs form hinges for folding the segments into the annular assembly.
Abstract:
The formation of a composite formed by spreading a liquid thermosetting resin over a continuously moving plastic film or sheet is disclosed. Chopped fiber is added and a fabric or veil, such as a dacron polyester cloth, is continuously laid over the top to form a reinforced composite. This continuously produced thermosetting resin composite is rolled into a coil. After a maturation period, the plastic film or sheet may be removed from the SMC composite and sections of appropriate size and weight are cut from the coil and placed over the die of a compression molding machine, veil side down, up or both. The material is then compression molded at a pressure of 500-3000 p.s.i (35 to 210 kg. per sq. cm.) and a temperature of 100.degree.-165.degree. C., and cured into an article. In another embodiment, the fabric or veil may be first placed on one of the die elements, e.g., the bottom die. SMC is then placed over the fabric to make up the total charge. The charge is then compression molded under the conditions previously described. The fabric used has a grab break strength of at least 10 lbs. (4.5 kg.) in both longitudinal and transverse directions, and a tensile elongation of at least 10%, and is sufficiently permeable to permit liquid resin to pass therethrough during compression molding.
Abstract:
The disclosure is of a method for cast-molding very thin (eggshell type) body members. The thin members are useful, for example, in model making as components of model vehicles such as model airplanes. By the method of the invention a high degree of control of the thickness of the molded members may be obtained and very strong members produced with integrally molded support members.
Abstract:
A pile product comprising a plurality of relatively long, thin face fibers extending from a base is molded from a crosslinkable polymeric material. During formation of the fibers, crosslinking of the polymeric material is initiated by heat activating a substance incorporated in the polymeric material which promotes crosslinking. Crosslinking imparts hot strength to the pile fibers so that the pile product, while still hot, can be removed from the mold without materially deforming the fibers. Consequently, the time it takes to mold the pile product is significantly reduced, thereby increasing productivity and lowering the cost of the product. Moreover energy is conserved because the mold is not continuously cycled between high and low extremes in temperature.
Abstract:
Method of making a mold for vacuum thermoforming is made by (a) applying a polyester gel coat to a master pattern; (b) applying a rigidizing mixture of a thermosetting resin and glass to the gel coat; (c) constructing and bonding an egg crate framework to the cured thermoset resin and glass fiber mixture; (d) filling the spacings of the egg crate framework with a polymeric rigidizing foam; (e) forming a vacuum plenum on the foam-filled egg crate; (f) attaching to the vacuum plenum a means for introducing a vacuum and; (g) forming air passageways through the gel coat which communicate with the vacuum plenum.
Abstract:
A process for making composite contoured sound insulating panels of a type suitable for use adjacent to structural panels of automobile vehicle bodies, which in accordance with one embodiment of the present invention, comprises forming a fibrous pad incorporating controlled amounts of a heat curable thermosetting binder and a heat softenable thermoplastic binder distributed in a controlled manner therethrough. The pad is subjected to a preliminary curing step to bond the fibers together into an integral mass, whereafter a dense liquid vinyl plastisol coating is applied to at least one face surface of the pad, which thereafter is heated to effect a fusion of the coating into a heat softened integral layer, effecting a simultaneous heat softening of the thermoplastic binder, whereafter the heated pad is placed between appropriately contoured mold surfaces and is compressed to impart a preselected contour thereto and localized embossments therein and a desired surface finish to the plastisol layer, while simultaneously cooling the pad to effect a rigidification of the thermoplastic binder and the layer so as to retain the composite pad in the preselected contoured and embossed configuration. In accordance with an alternative embodiment of the disclosed process, the pad is subjected to a preliminary molding step followed by the coating step and is subjected to a final molding step after the plastisol coating has been fused at an elevated temperature.