Compression mold assembly for forming a preform of a cascade includes first and second die elements and an axis of alignment. Line of removal of a formed preform is positioned perpendicular to a plane perpendicular to the axis of alignment. First die portion includes first curved surface forming interior surface of first strong back and second die portion includes first curved surface forming interior surface of a second strong back of a cell of a formed preform. Second die portion includes second curved surface forming an interior surface of a first vane on forward side of the cell of the formed preform and first die portion further includes first wall member which extends along line of removal and a second wall member which extends angularly from first wall portion forming an interior surface of a second vane positioned on an aft side of the cell.

A method for manufacturing a fiber formed body includes forming a fiber board into a predetermined outer shape while forming a pattern on an outer surface of the fiber board by compressing the fiber board, a forming at least one positioning member by compressing the fiber board, and positioning, relative to a cutoff device, the fiber board using the positioning member, and cutting off a cutoff target part of the fiber board using the cutoff device. In the method for manufacturing the fiber formed body, formation of the pattern during the forming of the outer shape and formation of the positioning member during the forming of the positioning member are simultaneously performed.

A method of manufacturing a fiber reinforced composite material lid for an utility vault including mixing an unsaturated polyester thermosetting matrix in to a resin paste, compounding the resin paste into a fiber reinforced composite material, maturing the compounded fiber reinforced composite material, cutting the matured compound into a charge pattern, molding the charge pattern in a mold cavity of a heated mold under low pressure to form the lid and cooling and machining the lid. The mold includes a cavity die and a core die having a shear angle for interfacing the core die within the cavity die and a steam pot for heating the cavity die and the core die, wherein the lid is molded between the cavity die and the core die and removed from the mold by a lid ejection mechanism.

An optical element includes a first substrate having a first surface, a resin member disposed on the first surface, and a second substrate disposed above the resin member with a joining member interposed therebetween. The resin member has a first region contacting the joining member and a second region surrounding the first region and not contacting the joining member. An inclined portion having a thickness increasing from a starting point located in the second region toward an outer circumference of the resin member, is disposed in the second region. A tangent of the first surface, orthogonal to a normal of the first surface passing through the starting point, and a straight line passing through the starting point and a point at which the inclined portion has a largest thickness, form an angle of 25° or more and 45° or less.

A method for forming a thermoplastic body having regions with varied material composition and/or porosity. Powder blends comprising a thermoplastic polymer, a sacrificial porogen and an inorganic reinforcement or filler are molded to form complementary parts with closely toleranced mating surfaces. The parts are formed discretely, assembled and compression molded to provide a unitary article that is free from discernible boundaries between the assembled parts. Each part in the assembly has differences in composition and/or porosity, and the assembly has accurate physical features throughout the sections of the formed article, without distortion and nonuniformities caused by variable compaction and densification rates in methods that involve compression molding powder blends in a single step.

An implantable medical device is disclosed comprising a thermoplastic composite body having anterior, first lateral, second lateral, posterior, superior, and inferior surfaces, and at least one dense portion and at least one porous portion which are integrally formed. The at least one dense portion is formed of a first thermoplastic polymer matrix that is essentially non-porous, and which is continuous through a thickness dimension from the superior surface to the inferior surface. The at least one porous portion is formed of a porous thermoplastic polymer scaffold having a second thermoplastic polymer matrix which is continuous through the thickness dimension. A method for forming the thermoplastic composite body is disclosed comprising disposing a first powder mixture in a first portion of a mold, disposing a second powder mixture in a second portion of the mold, simultaneously molding the first powder mixture and the second powder mixture, and leaching porogen.

There is provided method of manufacturing a knuckle for a vehicle. The method includes a preform forming operation of forming a preform serving as a preliminary molding object for forming the knuckle for a vehicle; and a main-molding-object forming operation of hot-pressing the preform to form a main molding object for forming the knuckle for a vehicle. The preform formed in the preform forming operation may be formed in a shape corresponding to a shape of the main molding object, and may be formed in a shape offset inward by a predetermined dimension from an outer shape of the main molding object.

Disclosed herein is a method of manufacturing heating elements for vehicle interior materials, which includes forming a base part having the same shape as a curved surface of a subject, forming an electrode part on an upper surface of the base part, and stacking a heating part on upper surfaces of the base part and electrode part. Accordingly, the heating element is manufactured in advance to have the same shape as the curved surface of the subject and then adhered to the subject so that the heating element is overlapped on and pressed against the subject without deformation. Thus, it is possible to make overall temperature distribution uniform and improve product quality.

Disclosed herein is a method of manufacturing heating elements for vehicle interior materials, which includes forming a base part having the same shape as a curved surface of a subject, forming an electrode part on an upper surface of the base part, and stacking a heating part on upper surfaces of the base part and electrode part. Accordingly, the heating element is manufactured in advance to have the same shape as the curved surface of the subject and then adhered to the subject so that the heating element is overlapped on and pressed against the subject without deformation. Thus, it is possible to make overall temperature distribution uniform and improve product quality.

The present invention addresses the problem of providing a molding method capable of molding a molded article having excellent strength and reducing manufacturing costs by shortening a molding cycle when obtaining a molded article from a fiber-reinforced thermoplastic resin by compression molding. The present invention relates to a molding method which obtains a fiber-reinforced thermoplastic resin by kneading a thermoplastic resin and a reinforcing fiber (14), and a molded article from the fiber-reinforced thermoplastic resin by compression molding. The molding method of the molded article comprising the fiber-reinforced thermoplastic resin according to the present invention comprises: a molding step for obtaining a first molded article from a predetermined amount of a fiber-reinforced thermoplastic resin through a molding die (4); a carrying-in step for opening the molding die (4), taking out the first molded article, and inserting the first molded article into a cooling die (5); and a compression cooling step for cooling the first molded article by compressing the first molded article through the cooling die (5).