Abstract: A deformable, coated radius filler composed of a continuous or elongated fibrous structure and a tacky, resin surface coating formed by pulling a dry, continuous or elongated fibrous structure through a heated resin bath. The coated radius filler has an inner portion that is substantially free of resin and the resin surface coating has a substantially uniform thickness.

Abstract: A prepared mold tool having a thermoplastic surface layer polymer coating on the mold surface of the mold tool or prepared prepreg having a thermoplastic surface layer polymer coating on the surface of the thermoplastic fiber reinforced prepreg are described that enhance first ply laydown of thermoplastic fiber reinforced composite prepregs onto mold tools for prepreg forming or in situ tape placement. Resulting thermoplastic fiber reinforced composite parts from a thermoplastic fiber reinforced thermoplastic composite material having structural reinforcement fibers with one or more high performance polymers, and a thermoplastic surface layer polymer coating which forms a polymer blend with the high performance polymers of the thermoplastic fiber reinforced composite material thereby imparting improved properties, and methods for making and using same, are provided herein.

Abstract: A resin infusion method that incorporates a melt-on-demand approach. The method includes: (a) providing a curable resin composition in the form of a block of frozen resin (20); (b) coupling the block of frozen resin (20) to an inlet port of a heated extruder (22), which comprises at least one rotating screw (24) housed within a heated barrel (25); (c) progressively melting the block of frozen resin (20) at the inlet port and concurrently feeding the melt resin through the heated barrel (25) to produce a liquid resin having a viscosity suitable for resin infusion; (d) continuously feeding the liquid resin exiting from the extruder to a mold, which contains a fibrous preform; and (e) introducing the liquid resin into the fibrous preform, wherein the block of frozen resin (20) provides an amount of resin composition sufficient for infusing the entire fibrous preform.

Abstract: A deformable, coated radius filler composed of a continuous or elongated fibrous structure and a tacky, resin surface coating formed by pulling a dry, continuous or elongated fibrous structure through a heated resin bath. The coated radius filler has an inner portion that is substantially free of resin and the resin surface coating has a substantially uniform thickness.

Abstract: A deformable, coated radius filler composed of a continuous or elongated fibrous structure and a tacky, resin surface coating formed by pulling a dry, continuous or elongated fibrous structure through a heated resin bath. The coated radius filler has an inner portion that is substantially free of resin and the resin surface coating has a substantially uniform thickness.

Abstract: A resin infusion method that incorporates a melt-on-demand approach. The method includes: (a) providing a curable resin composition in the form of a block of frozen resin (20); (b) coupling the block of frozen resin (20) to an inlet port of a heated extruder (22), which comprises at least one rotating screw (24) housed within a heated barrel (25); (c) progressively melting the block of frozen resin (20) at the inlet port and concurrently feeding the melt resin through the heated barrel (25) to produce a liquid resin having a viscosity suitable for resin infusion; (d) continuously feeding the liquid resin exiting from the extruder to a mold, which contains a fibrous preform; and (e) introducing the liquid resin into the fibrous preform, wherein the block of frozen resin (20) provides an amount of resin composition sufficient for infusing the entire fibrous preform.

Abstract: A prepared mold tool having a thermoplastic surface layer polymer coating on the mold surface of the mold tool or prepared prepreg having a thermoplastic surface layer polymer coating on the surface of the thermoplastic fiber reinforced prepreg are described that enhance first ply laydown of thermoplastic fiber reinforced composite prepregs onto mold tools for prepreg forming or in situ tape placement. Resulting thermoplastic fiber reinforced composite parts from a thermoplastic fiber reinforced thermoplastic composite material having structural reinforcement fibers with one or more high performance polymers, and a thermoplastic surface layer polymer coating which forms a polymer blend with the high performance polymers of the thermoplastic fiber reinforced composite material thereby imparting improved properties, and methods for making and using same, are provided herein.

Abstract: A prepared mold tool having a thermoplastic surface layer polymer coating on the mold surface of the mold tool or prepared prepreg having a thermoplastic surface layer polymer coating on the surface of the thermoplastic fiber reinforced prepreg are described that enhance first ply laydown of thermoplastic fiber reinforced composite prepregs onto mold tools for prepreg forming or in situ tape placement. Resulting thermoplastic fiber reinforced composite parts from a thermoplastic fiber reinforced thermoplastic composite material having structural reinforcement fibers with one or more high performance polymers, and a thermoplastic surface layer polymer coating which forms a polymer blend with the high performance polymers of the thermoplastic fiber reinforced composite material thereby imparting improved properties, and methods for making and using same, are provided herein.

Abstract: Embodiments of the present disclosure are directed to the targeted deposition of particles below 100 microns onto a substrate such as a film, tape, adhesive, fabric, fibers or a combination thereof. The targeted deposition may be accomplished by a dual-component electro-static deposition process. In one embodiment, the substrate having at least one layer of particles thereon may be combined with a prepreg. Prepregs manufactured according to embodiments of the invention may be used to manufacture composites with more robust mechanical and strength characteristics relative to conventional composites manufactured using conventional prepregs in addition to providing improved processed performance during the manufacture of the particle-coated substrate. In another embodiment, targeted deposition may be applied directly to a composite article to achieve similar benefits.

Abstract: Apparatus for producing spread fiber bundles by strategic use of tension control throughout the device and use of higher differential speeds between driven rollers and line speed of the running fiber bundle are provided herein, along with methods for producing spread fibers, prepregs, and articles of manufacture therefrom.

Abstract: Some embodiments herein are directed to a thermoplastic composite structure having at least one structural layer of fiber-reinforced thermoplastic resin and at least one toughening layer adjacent to a surface of the structural layer. The toughening layer is configured to create an interlaminar region in a composite laminate and may take the form of a polymer film, a woven or non-woven fibrous material free particles, a polymer layer or non-woven veil with toughening particles dispersed therein, metal mesh or toll.

Abstract: A deformable, coated radius filler composed of a continuous or elongated fibrous structure and a tacky, resin surface coating formed by pulling a dry, continuous or elongated fibrous structure through a heated resin bath. The coated radius filler has an inner portion that is substantially free of resin and the resin surface coating has a substantially uniform thickness.

Abstract: Apparatus for producing spread fiber bundles by strategic use of tension control throughout the device and use of higher differential speeds between driven rollers and line speed of the running fiber bundle are provided herein, along with methods for producing spread fibers, prepregs, and articles of manufacture therefrom.

Abstract: Embodiments of the present disclosure are directed to the targeted deposition of particles below 100 microns onto a substrate such as a film, tape, adhesive, fabric, fibers or a combination thereof. The targeted deposition may be accomplished by a dual-component electro-static deposition process. In one embodiment, the substrate having at least one layer of particles thereon may be combined with a prepreg. Prepregs manufactured according to embodiments of the invention may be used to manufacture composites with more robust mechanical and strength characteristics relative to conventional composites manufactured using conventional prepregs in addition to providing improved processed performance during the manufacture of the particle-coated substrate. In another embodiment, targeted deposition may be applied directly to a composite article to achieve similar benefits.