Abstract: Method of moulding a moulding material to form a moulded part of carbon fibre-reinforced resin matrix composite material in which a sheet moulding compound is moulded which can provide panels, for example for use as vehicle body panels, which have the combination of very low thickness, very light weight, very low warping and surface defects, and very low anisotropy with regard to localised fibre and resin distribution and their associated appearance and mechanical properties.

Abstract: The present invention describes a prepreg for the manufacture of fibre reinforced resin matrix composite materials, the prepreg comprising: a surface film comprising a thermosetting resin and a particulate filler material dispersed therein, and a fibrous layer on which the surface film is disposed, the fibrous layer comprising a plurality of non-woven carbon fibres which are substantially randomly oriented, wherein the fibrous layer has interstices between the carbon fibres dimensioned for absorbing at least a portion of the thermosetting resin during a resin infusion step and filtering at least a portion of the particulate filler material in the surface film to remain in the surface film during the resin infusion step.

Abstract: A composite panel including a multilayer laminate with a plurality of central plies of fibre reinforced resin matrix composite material, wherein at least one of the central plies includes a first fibrous layer of a plurality of non-woven carbon fibres which are substantially randomly oriented, and a rear reinforcement layer which is integrally moulded with the central multilayer portion the reinforcement layer being comprised of a rear ply of fibre reinforced resin matrix composite material, wherein the rear ply includes a second fibrous layer of a plurality of continuous fibres which extend continuously from at least one portion of a first edge of the rear ply to at least one portion of an opposite second edge of the rear ply.

Abstract: Method of moulding a moulding material to form a moulded part of carbon fibre-reinforced resin matrix composite material in which a sheet moulding compound is moulded which can provide panels, for example for use as vehicle body panels, which have the combination of very low thickness, very light weight, very low warping and surface defects, and very low anisotropy with regard to localised fibre and resin distribution and their associated appearance and mechanical properties.

Abstract: A prepreg comprising a fibrous material contacting a polymerizable resin, at least 50 wt % of the polymerizable resin comprising at least one polymerizable monomer having at least two carbon-carbon unsaturated functional groups, the monomer being polymerizable by reaction of the unsaturated functional groups to form a cured resin, wherein the resin has a heat of polymerization of less than 230 KJ/kg to provide a maximum increase in temperature of the prepreg of 60° C. during polymerization under adiabatic conditions.

Abstract: A composite panel composed of a fibre reinforced resin matrix composite material, wherein the panel comprises: a panel portion comprised of a first ply of fibre reinforced resin matrix composite material, wherein the first ply includes a first fibrous layer of a plurality of non-woven carbon fibres which are substantially randomly oriented, and a reinforcement portion which is integrally moulded with the panel portion and is located at a location on a surface of the panel portion to provide an integrally moulded primary structural region of the composite panel, the reinforcement portion being comprised of at least one second ply of fibre reinforced resin matrix composite material, the second ply comprising a second fibrous layer, wherein the first ply has a primary portion which is located in the primary structural region and a secondary portion which is adjacent to the primary portion and is located in a secondary structural region of the composite panel, wherein in the primary portion the first ply has a fi

Abstract: A composite panel composed of a fibre reinforced resin matrix composite material, wherein the panel comprises: a panel portion comprised of a first multilayer laminate including a plurality of first plies of fibre reinforced resin matrix composite material, wherein at least one of the first plies includes a first fibrous layer of a plurality of non-woven carbon fibres which are substantially randomly oriented, and a reinforcement portion which is integrally moulded with the panel portion and is located at one or more locations on a surface of the panel portion to provide one or more primary structural regions of the composite panel, the reinforcement portion being comprised of a second multilayer laminate including a plurality of second plies of fibre reinforced resin matrix composite material, wherein at least one of the second plies includes a second fibrous layer of a plurality of non-woven carbon fibres which are substantially randomly oriented, wherein in at least one primary structural region both the p

Abstract: A method of moulding a moulding material to form a laminated moulded part of fibre-reinforced resin matrix composite material, the method comprising the steps of: i. providing in a mould tool a preform comprising a central layer portion and a peripheral edge portion around at least a part of a periphery of the central layer portion, the central layer portion including at least one fibrous layer and a first resin, and the edge portion comprising a second resin including a plurality of individual fibres dispersed therein; ii. closing the mould tool to define a closed mould cavity containing the moulding material; and iii.

Abstract: A method of press molding a molding material to form a vehicle body panel of fiber-reinforced resin matrix composite material, the vehicle body panel having a front A-surface and a rear B-surface, the method comprising the steps of: i. providing a heated mold tool having a lower mold part and an upper mold part, the upper mold part having a first molding surface for molding a front A-surface of the vehicle body panel and the lower mold part having a second molding surface for molding a rear B-surface of the vehicle body panel; ii. providing a multilaminar panel of molding material comprising at least one layer of fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces, a surface resin layer of the multilaminar panel being at or adjacent to the first major surface; iii. locating the molding material in the mold tool; iv. closing the mold tool to define a substantially closed mold cavity containing the molding material; v.

Abstract: A method of manufacturing a foam body having an anisotropic cell structure, the method including the steps of: expanding a polymer at an elevated temperature to form an initial foam body; and cooling the initial foam body under a negative pressure. There is also provided a method of manufacturing a foam body having an anisotropic cell structure, the method including the steps of: (a) in a first expansion step, expanding a foamable polymer composition substantially isotropically to form an initial foam body having an isotropic cell structure; and (b) in a second expansion step, expanding the initial foam body anisotropically in a selected direction under a negative pressure which applies an expanding force in the selected direction to provide a final foam body having an anisotropic cell structure. Apparatus for the methods are also disclosed.

Abstract: A composite panel including a multilayer laminate with a plurality of central plies of fibre reinforced resin matrix composite material, wherein at least one of the central plies includes a first fibrous layer of a plurality of non-woven carbon fibres which are substantially randomly oriented, and a rear reinforcement layer which is integrally moulded with the central multilayer portion the reinforcement layer being comprised of a rear ply of fibre reinforced resin matrix composite material, wherein the rear ply includes a second fibrous layer of a plurality of continuous fibres which extend continuously from at least one portion of a first edge of the rear ply to at least one portion of an opposite second edge of the rear ply.

Abstract: A method of press moulding a moulding material to form a moulded part of fiber-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mould tool having a lower mould part and an upper mould part, the upper mould part having a first moulding surface for moulding a first moulded surface of the moulded part and the lower mould part having a second moulding surface for moulding a second moulded surface of the moulded part; ii. providing a multilaminar panel of moulding material comprising at least one layer of fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces, a surface resin layer of the multilaminar panel being at or adjacent to the first major surface and a dry fiber layer of the multilaminar panel forming the second major surface; iii.

Abstract: A method of press molding a molding material to form a molded part of fiber-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mold tool having a lower mold part and an upper mold part, the upper mold part having a first molding surface for molding a first molded surface of the molded part and the lower mold part having a second molding surface for molding a second molded surface of the molded part; ii. providing a multilaminar panel of molding material comprising at least one layer of dry fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces; iii. locating the molding material in the mold tool; iv. progressively closing the mold tool to define a substantially closed mold cavity containing the molding material, the closing step having: I. a first stage prior to both the first molding surface contacting the first major surface and the second molding surface contacting the second major surface and II.

Abstract: A method of press molding a molding material to form a molded part of fiber-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mold tool having a lower mold part and an upper mold part, the upper mold part having a first molding surface for molding a first molded surface of the molded part and the lower mold part having a second molding surface for molding a second molded surface of the molded part; ii. providing a multilaminar panel of molding material comprising at least one layer of fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces, a surface resin layer of the multilaminar panel being at or adjacent to the first major surface; iii. locating the molding material in the mold tool; iv. closing the mold tool to define a substantially closed mold cavity containing the molding material, the closing step including the sub-steps of: a.

Abstract: A method of press molding a molding material to form a molded part of fiber-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mold tool having a lower mold part and an upper mold part, the upper mold part having a first molding surface for molding a first molded surface of the molded part and the lower mold part having a second molding surface for molding a second molded surface of the molded part; ii. providing a multilaminar panel of molding material comprising at least one layer of fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces; iii. locating the molding material in the mold tool; iv. progressively closing the mold tool to define a substantially closed mold cavity containing the molding material, the closing step including: a. a preliminary closing phase to achieve mutual engagement between the lower and upper mold parts, b.

Abstract: A method of press molding a molding material to form a molded part of fiber-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mold tool having a lower mold part and an upper mold part, the upper mold part having a first molding surface for molding a first molded surface of the molded part and the lower mold part having a second molding surface for molding a second molded surface of the molded part; ii. providing a multilaminar panel of molding material comprising at least one layer of dry fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces; iii. locating the molding material in the mold tool; iv.

Abstract: The present invention describes a prepreg for the manufacture of fibre reinforced resin matrix composite materials, the prepreg comprising: a surface film comprising a thermosetting resin and a particulate filler material dispersed therein, and a fibrous layer on which the surface film is disposed, the fibrous layer comprising a plurality of non-woven carbon fibres which are substantially randomly oriented, wherein the fibrous layer has interstices between the carbon fibres dimensioned for absorbing at least a portion of the thermosetting resin during a resin infusion step and filtering at least a portion of the particulate filler material in the surface film to remain in the surface film during the resin infusion step.

Abstract: A laminated moulded part of fibre-reinforced resin matrix composite material, the moulded part comprising a first ply comprising fibres impregnated with a resin, an outer surface of the first ply defining an outer surface of the laminated moulded part, a rope located around at least a part of a periphery of the first ply, the rope comprising a plurality of strands of fibres twisted together and impregnated with a resin, a second ply comprising fibres impregnated with a resin, the second ply at least partly covering an inner surface of the first ply, at least a portion of a peripheral edge of the second ply being located inwardly of a corresponding portion of the rope, and at least a portion of the periphery of the first ply being folded over so as to wrap around the rope and cover the corresponding peripheral edge of the second ply.

Abstract: A prepreg comprising a fibrous reinforcement layer at least partially impregnated with a matrix resin having a first viscosity, a coating of a wet resin having a second viscosity on a first side of the fibrous reinforcement layer, the first viscosity being higher than the second viscosity, both the matrix resin and the wet resin being curable by ultraviolet radiation, a first removable flexible film which acts as a barrier to ultraviolet radiation on a second side of the fibrous reinforcement layer, and optionally a second removable protective flexible film covering the coating of wet resin.

Abstract: A method of press moulding a moulding material to form a moulded part of fibre-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mould tool having a lower mould part and an upper mould part, the upper mould part having a first moulding surface for moulding a first moulded surface of the moulded part and the lower mould part having a second moulding surface for moulding a second moulded surface of the moulded part; ii. providing a multilaminar panel of moulding material comprising at least one layer of dry fibres and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces; iii. locating the moulding material in the mould tool; iv. progressively closing the mould tool to define a substantially closed mould cavity containing the moulding material, the closing step having: I.