A system for manufacturing a shell for a batting helmet includes interchangeable mold-core portions configured to form a cavity for receiving molding material. The mold-core portions include a first base mold-core portion and a plurality of inner side mold-core portions configured to form an interior contour of the shell. The mold-core portions further include a second base mold-core portion and a plurality of outer mold-core portions configured to form an exterior contour of the shell. Mold-core portions are interchangeable, removable, and replaceable from an interlocked position relative to other mold-core portions. A method of manufacturing batting helmet shells includes selecting mold-core portions corresponding to various helmet shell configurations having various protective features, assembling the mold-core portions into a mold assembly, and providing molding material into a cavity in the mold assembly. A kit of parts for making a shell for a batting helmet includes a variety of interchangeable mold-core portions.

A manufacturing method of a mold includes the steps of: providing an aluminum base in the shape of a hollow cylinder which is made of a AlMgSi based aluminum alloy, the aluminum base being mechanically mirror-finished; performing a frosting treatment on a surface of the aluminum base with an aqueous solution which contains a salt of hydrogen fluoride and ammonium; thereafter, forming an inorganic material layer on the surface of the aluminum base and forming an aluminum film on the inorganic material layer, thereby forming a mold base; and alternately repeating anodization and etching on a surface of the aluminum film of the mold base, thereby forming an inverted moth-eye structure which has a plurality of micro recessed portions.

A manufacturing method of a mold includes the steps of: providing an aluminum base in the shape of a hollow cylinder which is made of a AlMgSi based aluminum alloy, the aluminum base being mechanically mirror-finished; performing a frosting treatment on a surface of the aluminum base with an aqueous solution which contains a salt of hydrogen fluoride and ammonium; thereafter, forming an inorganic material layer on the surface of the aluminum base and forming an aluminum film on the inorganic material layer, thereby forming a mold base; and alternately repeating anodization and etching on a surface of the aluminum film of the mold base, thereby forming an inverted moth-eye structure which has a plurality of micro recessed portions.

The present invention provides an improvement relating to a method for producing a fiber-reinforced resin article at least partially having a structure comprising a bent or curved wall surface, such as a hollow structure part or a U-shaped cross-sectional structure part. A method for manufacturing a fiber-reinforced resin article according to the present invention has a molding step of heating, in a press metal mold, a prepreg preform together with a core comprising a wax material to obtain a cured product and a core removal step of removing the core from the cured product, where the core has an expansion part comprising a first wax material and a stamper part comprising a second wax material that is incompatible with the first wax material, the stamper part is disposed on a surface of the core, and a portion mirroring a shape of a surface of the stamper part is formed on a surface of the cured product.

The present invention provides an improvement relating to a method for producing a fiber-reinforced resin article at least partially having a structure comprising a bent or curved wall surface, such as a hollow structure part or a U-shaped cross-sectional structure part. A method for manufacturing a fiber-reinforced resin article according to the present invention has a molding step of heating, in a press metal mold, a prepreg preform together with a core comprising a wax material to obtain a cured product and a core removal step of removing the core from the cured product, where the core has an expansion part comprising a first wax material and a stamper part comprising a second wax material that is incompatible with the first wax material, the stamper part is disposed on a surface of the core, and a portion mirroring a shape of a surface of the stamper part is formed on a surface of the cured product.

A main object of the present invention is to provide beneficial improvements relating to a method for producing a fiber reinforced plastic product, the method including curing while pressurizing a prepreg preform by using a core having a fusible part as means for pressurizing. A method for producing a fiber reinforced plastic product, the method including: a core preparation step of preparing a core comprising a fusible part and an outer skin covering the fusible part; a molding step of disposing a prepreg preform inside a mold together with the core, and heating and pressurizing the prepreg preform in the mold to obtain a cured product; and a core removal step of removing materials of the fusible part from the cured product, in the molding step, at least a portion of the prepreg preform being pressurized by expansion of the core, in which the fusible part comprises a first fusible part and a second fusible part having a fusion temperature higher than that of the first fusible part, a material of the first fusible part and a material of the second fusible part are incompatible with each other, and in the molding step, the first fusible part fuses partially or entirely, while the second fusible part does not fuse partially or entirely.

Processes, systems, and methods described herein can be used for manufacturing reinforced carbon fiber structures. For example, processes can include forming a plurality of foam substructures. The foam substructures can be made of heat expanding foam that further expands when heated to a first threshold temperature. Processes can also include positioning carbon fiber on at least a portion of surfaces of the foam substructures, assembling the plurality of foam substructures with the carbon fiber into a superstructure, wrapping an outer surface of the superstructure with additional carbon fiber to form a wrapped superstructure, and curing the wrapped superstructure within a mold to form a reinforced carbon fiber structure. The reinforced carbon fiber structures can include internal truss structures within the foam. The reinforced carbon fiber structures can be used to form reinforced carbon fiber bicycle frame components.

There is disclosed an apparatus for winding filaments to form a structure. The apparatus includes a carrier which mounts spools of fiber, a mandrel, and a guide element which directs fiber tows, comprising filaments from the spools, onto the mandrel. The system further includes a heating element which applies heat to the fiber tows, and a diaphragm element which defines an orifice about the mandrel. The diaphragm element includes one or more displaceable portions which define a physical dimension of the orifice and which: displace to vary the physical dimension of the orifice; and apply a predetermined pressure to the fiber tows disposed on the mandrel. Also disclosed and described is a related method.

A composite material structure manufacturing jig (10) is used when manufacturing a composite material structure by adhering prepreg to a framework structure including a frame component that includes a channel extending along a longitudinal direction of the frame component. The composite material structure manufacturing jig (10) is inserted in the channel of the frame component and used therein. The jig (10) includes a tubular body (11) formed of an elastic material containing a reinforcement fiber, the body (11) including a trapezoidal transverse section that is a cross section orthogonal to a longitudinal direction of the body (11), the trapezoidal transverse section including an upper base and a lower base longer than the upper base. An inner surface of the body (11) is coated with an inner peripheral film (16) serving as a gas barrier layer.

A seal configuration, mold and manufacturing process that inhibits undesirable elastomer migration onto critical radially inwardly facing portions of a plastic-lined dynamic sealing lip, for improved high-pressure seal operation.