In particular embodiments, a process for producing bulked continuous carpet filament from recycled polymer utilizes two vacuum pumps (140A, 140B) in combination with a single extruder (100). In various embodiments, the dual vacuum arrangement (e.g., at least two vacuum pumps (140A, 140B)) operably coupled to the single extruder (e.g., MRS extruder (100)) may be configured to remove one or more impurities from recycled polymer as the recycled polymer passes through the extruder.

A procedure for repairing a polymer matrix composite component is provided. The procedure includes the steps of: providing a polymer matrix composite component having a site prepared for repair by removal of damaged or defective material; locating an uncured, polymer matrix composite repair patch at the site to re-build the component thereat; and curing the polymer matrix of the repair patch by heating the patch using eddy currents induced by one or more alternating current coils. The repair patch is without metallic additives, such that the repaired polymer matrix composite after the curing step is also without metallic additives in the vicinity of the repair patch.

The invention relates to a method for producing fiber-reinforced composite parts by means of vacuum infusion of a reactive resin mixture, characterized in that the steps of production of the reactive resin mixture and injection into the cavity are carried out in an infusion device in immediate temporal succession.

A method for molding a composite material and a device for molding a composite material are provided which are able to suppress the occurrence of voids in a composite material and improve the mechanical characteristics and appearance quality of the composite material. In the method for molding a composite material (10), a seal region (270) including a cavity (250) in which a reinforcing base material (11) is disposed and an outer peripheral region (260) that communicates with an outer periphery of the cavity is air-tightly sealed by means of a first sealing member (310). Then, an operation of suctioning a gas from the outer peripheral region to evacuate the gas in the seal region is started, and a resin (12) is injected into a part of the cavity. Next, a mold (200) is clamped to provide a liquid-tight seal between the cavity and the outer peripheral region by means of a second sealing member (320) while pressing the resin to fill the cavity with the resin. After that, the operation of suctioning the gas from the outer peripheral region is stopped.

A method for producing a plastic tank includes preparing a tank wall as a hot extrudate. A reinforcing sheet is then attached to at least one region of the outer layer of the hot extrudate. After introducing the attached reinforcing sheet and the hot extrudate into a shaping tool, the shaping tool performs shaping of the hot extrudate and the attached reinforcing sheet to form the tank wall, while simultaneously enhancing the attachment of the reinforcing sheet to the tank wall.

The invention is directed to a process for producing a cured 3D product comprising the following steps: (a) providing a form negative mould of the 3D product comprising of one or two formed plastic sheets as obtained by thermoforming corresponding with the shape of the 3D product; (b) adding a liquid curable composition to the mould such that the inner surface of the mould is covered by the curable composition; and (c) solidifying the curable composition wherein a solidified layer or body is formed having the shape of the 3D product; wherein the cured 3D product is a radiation cured 3D product; and wherein the step (c) a radiation curable composition is solidified by radiation through the plastic sheet of the mould to form a solidified layer having the shape of the 3D product.

A method for forming a three-dimensional curved surface on a laminated substrate is provided. In the method, the laminated substrate is brought into close contact with an elastic sheet. Here, the laminated substrate comprises a support substrate and a conductive layer on the support substrate, and the support substrate comprises a resin substrate comprising a thermoplastic resin. The elastic sheet is deformed while the laminated substrate is in close contact with the elastic sheet. The laminated substrate is brought into close contact with a temperature-controlled mold to soften the resin substrate.

A system for forming a deep drawn helmet and method therefor are disclosed. The system includes a forming draw ring and a non-forming draw ring and supports a prepreg stack between a forming aperture of the forming draw ring and a non-forming aperture of the non-forming draw ring. The system clamps a flange portion of the prepreg stack between a contact surface of the forming draw ring and a contact surface of the non-forming draw ring, which forms a clamped assembly of the rings and the prepreg stack. The system then forms a deep drawn helmet preform from the prepreg stack of the clamped assembly. The same system or a different forming system then consolidates one or more of the preforms into a final deep drawn helmet. The system can control sliding of the flange during forming of the helmet preform without reducing the flange clamping force.

A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

A flat laminate element made of thermoplastic is hot-formed in a two-stage method. In a first stage, the flat laminate which includes film(s) and/or panels(n) is placed on a flat frame-shaped pallet and is heated to a forming temperature in a heating zone between two flat heat screens in a contactless manner. The edge zone of the hot flat laminate element lies on the pallet such that the laminate piece cannot be clamped in a first laminate direction but rather can be slide on the pallet in this direction. Two non-flat rigid contours which are identical or largely identical act on two opposing parallel laminate edge sections uniaxially and perpendicularly to the laminate plane and only in the first laminate direction, i.e. monodirectionally, and shape the entire heated laminate element into a monodirectionally molded blank.