Sony Corporation

US Government As Represented by the Secretary of the Army

Aluminum Company of America

Micro Contacts, Inc.

John Gillespie

Curt Delanoy

Roderic C Don

Bruce K Fink

Cynthia L Lambing

Scott Holmes

Emanuele Gillio

Stephen M Andersen

Karl Bernetich

Scott Leach

A composite carbon fiber material is formed of one or more layers of carbon fiber material in which the carbon fibers are aligned all in the same direction and a mat of nonwoven, woven, or off-axis unidirectional carbon fibers are laminated together. Layers may be used individually or as a hybrid. The layers can be preimpregnated or impregnated during processing using thermoplastic or thermosetting resins. A layer of thermoplastic resin is applied either over the surface or within the composite structure, and the resin permeates the material so as to provide a more stable mechanical structure once the resin is processed. The material combines good mechanical strength with improved electrical current carrying properties when compared with the aligned carbon fiber layer alone. The layering sequence, layer type, and resin type can be specified to tailor electrical properties, mechanical properties, durability, and wear resistance. The resultant material achieves these results in substantially smaller material thickness than previously available.

Composite carbon fiber material and method of making same

Multiple resin transfer molding is the simultaneous injection of differing esins in fiber preforms with or without a separation layer. The flow of the resins is controlled by varying the permeabilities of the preforms and the separation layer. The method produces multifunctional hybrid composites made of multilayered preforms and multiple resins. A fundamental advantage of the invention is the simplification of the manufacturing process.

One-step resin transfer molding of multifunctional composites consisting

A method and apparatus for automated resistance welding of materials is provided. The material may be thermoplastic material. The material has a layer of a second material adjacent thereto. The second material is a dissimilar material which may be applied as a film or a coating on the first material, or the second material may be a separate layer placed adjacent the first material. A heating element is placed in the interface between overlapping portions of the two pieces of material to be welded together. The layers are directly adjacent to the heating element. The layers can be consolidated onto the heating element if desired. The heating element can be composed of carbon fibers in a polymer matrix. The heating element is supplied with current to generate resistive heating. The heating causes melting of the layers adjacent to and contacting the material. Pressure is applied to the area being welded to fuse the materials together. A lower pressure may be applied as a clamping force to areas adjacent to the welded area. The welding may be performed in a step wise fashion to separate weld segments or substantially completely to the entire weld joint. A cooling mechanism is also provided. The weld is simultaneously inspected for the occurrence of melting and for bond quality. A control system is provided for full automation of the system.

Apparatus and method for resistance welding

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Hockessin, DE, United States of America

John Gillespie