Abstract: A product sheet of composite material can be made by disposing composite materials of composite material in adjacent (side-by-side) relation with each other. The composite materials comprise fibers in a thermoplastic matrix material. The adjacent composite materials are bonded together to provide a product sheet of composite material. Preferably, a cross ply of composite material is disposed on the composite materials. The cross ply may be a unidirectional sheet and the fibers in the cross ply may be disposed in transverse relation to the fibers in the composite materials.

Abstract: A structural tie 10 is made from at least one layer of composite material 20. The composite material has a polymer matrix filled with at least one reinforcing material. In one embodiment, the matrix is a thermoplastic and the reinforcing material is fibers encapsulated by the thermoplastic. A structural tie 10 may be selectively formable, in situ, by applying heat to cause the matrix material to soften. Once softened, the structural tie can be conformed to an adjacent surface. The structural tie may include layers 20, 22 of composite material bonded to one another. Optionally, the structural tie is a hybrid of a composite material and a metallic material bonded together. A structural tie may be heat-bondable to a structural member 24.

Abstract: A product sheet of composite material can be made by disposing composite materials of composite material in adjacent (side-by-side) relation with each other. The composite materials comprise fibers in a thermoplastic matrix material. The adjacent composite materials are bonded together to provide a product sheet of composite material. Preferably, a cross ply of composite material is disposed on the composite materials. The cross ply may be a unidirectional sheet and the fibers in the cross ply may be disposed in transverse relation to the fibers in the composite materials.

Abstract: A product sheet of composite material can be made by disposing composite materials of composite material in adjacent (side-by-side) relation with each other. The composite materials comprise fibers in a thermoplastic matrix material. The adjacent composite materials are bonded together to provide a product sheet of composite material. Preferably, a cross ply of composite material is disposed on the composite materials. The cross ply may be a unidirectional sheet and the fibers in the cross ply may be disposed in transverse relation to the fibers in the composite materials.

Abstract: A blade comprises a lightweight core, a composite material disposed on the core, and a skin located on the composite material. The composite material comprises fibers incorporated into a thermoplastic resin matrix in the form of a prepreg sheet or wet layup. The rotor blade may also comprise a front edge member attached along at least a portion of a leading edge of the core, a rear edge member attached along at least a portion of a trailing edge of the core, and a skin located over the core, the front edge member, and the rear edge member. The rotor blade may also comprise a spar extending through the core along a longitudinal axis of the rotor blade, and a skin located over the core and the spar. The edge members and the spars may be fabricated from thermoplastic material.

Abstract: A composite laminate is made by providing at least a first composite ply and a second composite ply, each having longitudinally oriented fibers in a thermoplastic matrix. The second composite ply is disposed on, and in transverse relation to, the first composite ply. Preferably, the second ply is disposed at 90° relative to the first ply. An article can be manufactured by providing a core material and applying a reinforcing material to a portion of the core material. The reinforcing material is a reinforcing composite ply or a composite laminate as described herein. Optionally, the core material is a prepreg that may be a composite laminate.

Abstract: A moldable composite material contains flakes of composite material, i.e., flakes of polymeric matrix materials having fibers embedded therein. An improved substrate is provided by providing a substrate and applying a coating onto the substrate, the coating containing the flakes of composite material. A first construction member can be secured to a second construction member by applying the coating onto an attachment region of the first construction member, and applying a fastener onto the first construction member in the coated attachment region to secure the first construction member to the second construction member.

Abstract: A panel had a first face and a second face, including a strike face portion having a first plurality of plies each containing fibers in a matrix material. There is a support portion adjacent to the strike face portion, the support portion containing a second plurality of plies each having fibers in a matrix material. Each ply is bound to an adjacent ply and the first fibers are lower-performing relative to the second fibers. Protection from a ballistic threat may be provided by providing such a panel with the strike face disposed toward the threat. In another aspect, a composite ballistic panel may contain fibers in a thermoplastic matrix material, to the substantial exclusion of thermosetting matrix materials.

Abstract: A structural tie 10 is made from at least one layer of composite material 20. The composite material has a polymer matrix filled with at least one reinforcing material. In one embodiment, the matrix is a thermoplastic and the reinforcing material is fibers encapsulated by the thermoplastic. A structural tie 10 may be selectively formable, in situ, by applying heat to cause the matrix material to soften. Once softened, the structural tie can be conformed to an adjacent surface. The structural tie may include layers 20, 22 of composite material bonded to one another. Optionally, the structural tie is a hybrid of a composite material and a metallic material bonded together. A structural tie may be heat-bondable to a structural member 24.

Abstract: A composite laminate is made by providing at least a first composite ply and a second composite ply, each having longitudinally oriented fibers in a thermoplastic matrix. The second composite ply is disposed on, and in transverse relation to, the first composite ply. Preferably, the second ply is disposed at 90° relative to the first ply. An article can be manufactured by providing a core material and applying a reinforcing material to a portion of the core material. The reinforcing material is a reinforcing composite ply or a composite laminate as described herein. Optionally, the core material is a prepreg that may be a composite laminate.

Abstract: A panel had a first face and a second face, including a strike face portion having a first plurality of plies each containing fibers in a matrix material. There is a support portion adjacent to the strike face portion, the support portion containing a second plurality of plies each having fibers in a matrix material. Each ply is bound to an adjacent ply and the first fibers are lower-performing relative to the second fibers. Protection from a ballistic threat may be provided by providing such a panel with the strike face disposed toward the threat. In another aspect, a composite ballistic panel may contain fibers in a thermoplastic matrix material, to the substantial exclusion of thermosetting matrix materials.