Abstract: The present invention provides for a method of manufacturing a preform for a RTM molding process that will increase both the handling capability of the preform and the final part quality. The invention consists of applying a patterned discontinuous layer of liquid resin over at least one side of a layer of reinforcing fibers. The resin film can consist of a homogeneous liquid, an aqueous dispersion or a melted resin applied at an elevated temperature. In one embodiment, there is present a roller having a patterned surface. Liquid resin is applied to the surface of the patterned roller via a second roller. The layer of reinforcing fibers is passed by the roller in such a fashion that the resin from the pattern on the surface of the roller is transferred to the layer of reinforcing fibers. The contact of the roller with the layer of reinforcing fibers is sufficient to force some of the resin into the fibers themselves.

Abstract: A fiber reinforced composite article is made by providing a plurality of layers of first, substantially dry, unimpregnated reinforcing fibers, sometimes called in-plane fibers. Such layers are stacked into a preform of a stack of layers. While in the dry, unimpregnated condition, a plurality of spaced apart second reinforcing members are inserted into the preform at an angle, for example transversely, to the stack of layers. In this condition, the preform is impregnated with a matrix about the first reinforcing fibers and the second reinforcing members. The article product comprises the plurality of stacked layers of the first reinforcing fibers and the plurality of the spaced apart second reinforcing members disposed beside or adjacent the first reinforcing fibers, with a substantially solid matrix disposed about the reinforcing fibers and members.

Abstract: A composite article, for example a blading member of a gas turbine engine, comprising a plurality of stacked layers of reinforcing fibers bonded together with a matrix resin is provided with enhanced resistance to impact cracking, material loss and/or delamination though use of a matrix resin including properties comprising a tensile strain property of at least 5% and a K1c toughness of at least about 850 psi·inch1/2. A method for making such a composite article with such resin comprises providing the layers of reinforcing fibers in a substantially dry, unimpregnated condition. The dry layers are stacked as a preform in a mold cavity and impregnated with the resin to wet and impregnate the dry layers of the preform. Then the resin is cured as a matrix about the fibers and the stacked layers.

Abstract: A fiber reinforced composite article is made by providing a plurality of layers of first, substantially dry, unimpregnated reinforcing fibers, sometimes called in-plane fibers. Such layers are stacked into a preform of a stack of layers. While in the dry, unimpregnated condition, a plurality of spaced apart second reinforcing members are inserted into the preform at an angle, for example transversely, to the stack of layers. In this condition, the preform is impregnated with a matrix about the first reinforcing fibers and the second reinforcing members. The article product comprises the plurality of stacked layers of the first reinforcing fibers and the plurality of the spaced apart second reinforcing members disposed beside or adjacent the first reinforcing fibers, with a substantially solid matrix disposed about the reinforcing fibers and members.

Abstract: A fiber reinforced composite article is made by providing a plurality of layers of first, substantially dry, unimpregnated reinforcing fibers, sometimes called in-plane fibers. Such layers are stacked into a preform of a stack of layers. While in the dry, unimpregnated condition, a plurality of spaced apart second reinforcing members are inserted into the preform at an angle, for example transversely, to the stack of layers. In this condition, the preform is impregnated with a matrix about the first reinforcing fibers and the second reinforcing members. The article product comprises the plurality of stacked layers of the first reinforcing fibers and the plurality of the spaced apart second reinforcing members disposed beside or adjacent the first reinforcing fibers, with a substantially solid matrix disposed about the reinforcing fibers and members.

Abstract: The present invention provides for a method of manufacturing a preform for a RTM molding process that will increase both the handling capability of the preform and the final part quality. The invention consists of applying a patterned discontinuous layer of liquid resin over at least one side of a layer of reinforcing fibers. The resin film can consist of a homogeneous liquid, an aqueous dispersion or a melted resin applied at an elevated temperature. In one embodiment, there is present a roller having a patterned surface. Liquid resin is applied to the surface of the patterned roller via a second roller. The layer of reinforcing fibers is passed by the roller in such a fashion that the resin from the pattern on the surface of the roller is transferred to the layer of reinforcing fibers. The contact of the roller with the layer of reinforcing fibers is sufficient to force some of the resin into the fibers themselves.