Abstract: A multifunctional surfacing material capable of providing lightning strike protection (LSP) and burn-through resistance. In one embodiment, the multifunctional surfacing material is composed of a conductive layer positioned between two resin layers, at least one of which contains one or more fire retardant compounds. In another embodiment, the multifunctional surfacing material is composed of a conductive layer positioned between two resin layers one of which is a thermally-stable layer. The surfacing material is co-curable with a composite substrate, e.g. prepreg or prepreg layup, which contains fiber-reinforced matrix resin.

Abstract: A method for the manufacturing of three-dimensional (3D) preforms and composite structures having non-planar surfaces and flanges such that the fibrous or composite material used for shaping the final 3D structure has the necessary length and surface area to conform to the desired contours of the molding tool without wrinkling. The manufacturing method begins with the formation of an intermediate preform blank by automated placement of fiber tapes or prepreg tapes, followed by shaping the blank on a molding tool with 3D contours to form the final 3D structure.

Abstract: A surfacing material that is capable of ultraviolet (UV) protection. The surfacing material is a multilayer structure composed of a woven peel ply fabric interposed between a first curable resin layer and a second curable resin layer. The surfacing material is designed to be co-cured with a composite substrate, for example, a prepreg layup. Upon curing, the peel ply fabric combined with the outer thermoset layer function as a UV protective layer. When the peel ply fabric and the outer thermoset layer are removed, a paint-ready surface is revealed. Such surface does not require any surface preparation prior to painting.

Abstract: Disclosed herein are fully automated methods for shaping a composite material.

Abstract: A composite material having at least two layers of reinforcing fibers impregnated with a curable resin; an interlaminar region formed between adjacent layers of reinforcing fibers; and a combination of polymeric toughening particles and fire-retardant particles in the interlaminar region.

Abstract: Multifunctional surfacing materials for use in composite structures are disclosed. According to one embodiment, the surfacing material includes (a) a stiffening layer, (b) a curable resin layer, (c) a conductive layer, and (d) a nonwoven layer, wherein the stiffening layer (a) and the nonwoven layer (d) are outermost layers, and the exposed surfaces of the outermost layers are substantially tack-free at room temperature (20° C. to 25° C.). The conductive layer may be interposed between the curable resin layer and the stiffening layer or embedded in the curable resin layer. According to another embodiment, the surfacing material includes a fluid barrier film between two curable resin layers. The surfacing materials may be in the form of a continuous or elongated tape that is suitable for automated placement.

Abstract: A curable composition containing more than 80% by weight of a blend of benzoxazines, wherein the blend includes (A) one or more multifunctional benzoxazines and (B) a liquid, non-halogenated monofunctional benzoxazine. This composition has been found to be stable at high temperatures, e.g. 180° C.-250° C., and suitable for making composite materials using conventional techniques such as prepregging and liquid resin infusion.

Abstract: Methods are provided for improved recovery of organic salts, such as ionic liquids or organic salts comprising quaternary organic cations, in an industrial alumina production process, such as the Bayer process. These methods include (i) using an organic salt for the removal of impurities in an industrial process for the production of alumina; (ii) subjecting the spent organic salt to a recycling operation that generates at least one exit stream having a measureable amount of the organic salt {e.g., by entrainment or by solubility of the organic salt in the exit stream); (iii) collecting and treating the exit stream (s) with an inorganic salt, in an amount effective to induce phase separation; and (iv) recovering the organic phase containing the recovered organic salt. These methods and compositions allow alumina refinery plants to use organic salts for removal of industrial process streams in an economical manner, due to the efficient recovery of the organic salt.

Abstract: Disclosed herein are devices and methods for manufacturing uncured, near-net shape plies. Such devices include: a plurality of spools, each dispensing a dry tow; optionally, a plurality of spreaders to spread the dry tows; optionally, a means to combine the dry tows into a plurality of tapes or bundles; a plurality of feeders, each carrying a tow, tape or bundle, and adapted to maintain the tows, tapes or bundles in a parallel arrangement; a cutting apparatus adapted to independently cut each individual tow, tape or bundle to a pre-determined length; optionally, a conveyor adapted to transport the cut tows, tapes or bundles away from the cutting apparatus; an in-line resin infuser adapted to impregnate the dry tows, tapes or bundles with resin material; and a receiver for the cut tows, tapes or bundles, wherein the cut tows, tapes or bundles are impregnated and configured in the form of a near-net shape ply.

Abstract: Coating compositions having a polymeric binder and a stabilizer composition including at least one of a UV absorber, a hindered amine light stabilizer (HALS), or an inorganic UV blocker are provided herein, wherein said coating compositions are more resistant to discoloration when exposed to UV-C (190-280 nm) light compared to the coating compositions in the absence of the stabilizer composition. Thus, a method of stabilizing a coating composition against the deleterious effects of UV-C (190-280 nm) light includes adding to the coating composition an effective amount of such a stabilizer composition, wherein the coating composition is made more resistant to discoloration when exposed to UV-C (190-280 nm) light compared to the coating composition in the absence of the stabilizer composition. Coated articles can be made from the coating composition, and methods of making stabilized coating films include adding the stabilizer composition to the coating composition.

Abstract: Disclosed herein are methods for isolating a composite material from the environment, as well as the isolated composite material. Also disclosed herein are methods for shaping a composite material that include the use of isolated composite materials. For example, disclosed is a method for mechanical thermoforming of a composite material to form a shaped composite material.

Abstract: Stabilizer compositions having a stabilizing amount of at least one co-active agent; an ultraviolet light absorber chosen from an ortho-hydroxy benzophenone, and/or an ortho-hydroxyphenyl benzotriazole; and a hindered amine light stabilizer, are provided herein, along with masterbatch concentrates containing same, and processes for using same for stabilizing polymeric organic materials to protect against light and thermal degradation due to exposure to UV irradiation.

Abstract: Disclosed herein are methods for isolating a composite material from the environment, as well as the isolated composite material. Also disclosed herein are methods for shaping a composite material that include the use of isolated composite materials. For example, disclosed is a method for mechanical thermoforming of a composite material to form a shaped composite material.

Abstract: Disclosed herein are methods for isolating a composite material from the environment, as well as the isolated composite material. Also disclosed herein are methods for shaping a composite material that include the use of isolated composite materials. For example, disclosed is a method for mechanical thermoforming of a composite material to form a shaped composite material.

Abstract: The present disclosure relates generally to carbon fibers having high tensile strength and modulus of elasticity, as well as a process for the manufacture of such carbon fiber. The process comprises spinning a polymer/solvent solution into a solvent/water bath in the range of 78%-85% solvent, thereby producing a dense fiber structure, and subsequently carbonizing the polymer precursor fiber at a lower than typical carbonization temperature to form carbon fibers.

Abstract: A method for surface preparation of composite substrates prior to adhesive bonding. A curable surface treatment layer containing blocked isocyanate compounds is applied onto a curable composite substrate, followed by co-curing. The surface treatment layer may be a resin layer without fibers or a removal peel ply composed of resin-impregnated fabric. After surface preparation, the composite substrate is provided with a chemically-active, bondable surface that can be adhesively bonded to another composite substrate to form a covalently-bonded structure.

Abstract: A bonding method for joining two structural parts using a curable adhesive layer having a fibrous veil embedded therein. The fibrous veil carries a polymeric binder, which is in a solid phase at room temperature (20° C.-25° C.) and is capable of dissolving into the adhesive composition during curing thereof.

Abstract: Hydrometallurgical solvent extraction processes for recovering value metal ion species such as any of manganese, cobalt, nickel, and/or lithium from solutions derived from recycled electronics and/or batteries and containing mixed-metal ions by separating the value metal ions using selective stripping techniques as herein described, are provided.

Abstract: Polymer compositions for making stabilized polymeric articles that are resistant to at least one deleterious effect of discoloration, cracking, or crazing upon exposure to UV-C (190-280 nm) light are provided herein, wherein the polymer compositions include: (i) an organic polymeric material; and (ii) a stabilizer composition comprising: an antioxidant selected from the group consisting of hindered phenols, phosphites and phosphonites, and mixtures thereof; and a light stabilizer selected from the group consisting of hindered amine light stabilizers (HALS), UV absorbers (UVA), hindered benzoates, and mixtures thereof, even where barium compounds (such as barium salts) are absent from the stabilizer composition, and with the proviso that the HALS is not bis(2,2,6,6,-tetramethyl-4-piperidyl) sebacate (TINUVIN™ 770) alone.

Abstract: Polymer compositions for making a stabilized polymeric articles that are resistant to discoloration upon exposure to UV-C light having: (i) an organic polymeric material; and (ii) a hindered phenol, organic phosphite, or a combination thereof, with the provisos that: (a) the OH group on the aromatic ring of the hindered phenol is flanked by two tertiary hydrocarbyl groups, and (b) the organic phosphite does not have any —OAr group linked directly to the P atom of the phosphite, wherein Ar represents an unsubstituted or substituted aryl group, are provided herein. Reduced discoloration is associated with the use of specific hindered phenols and the organic phosphites compared to other hindered phenols and organic phosphites, even in the absence of other polymer additives including UV absorbers, hindered amine light stabilizers (HALS), metal oxides and/or barium salts.