Abstract: A conductive wire includes a thermoplastic filament having a circumference and a plurality of coating layers dispersed about the circumference of the thermoplastic filament. The coating layers include a plurality of conductive layers comprising aligned carbon nanotubes dispersed therein and at least one thermoplastic layer between each pair of conductive layers.

Abstract: A method for using a tow incorporating a large number of fibers to form a composite part that has the quality of parts made with tows incorporating a small number of fibers is described. The method includes spreading the tows incorporating a large number of fibers to form a relatively wide, flat, and continuous, unidirectional fabric, holding the fabric under tension to maintain the orientation and flatness, subjecting the flattened fabric to melt-bonding while held under tension to maintain the flattened configuration, and slicing the melt-bonded, unidirectional fabric into a plurality of narrow fiber tows and subsequently using these to produce braided, woven, and other fabric forms.

Abstract: Materials and Methods are provided for producing preform materials for impact-resistant composite materials suitable for liquid molding. An interlayer comprising a spunbonded, spunlaced, or mesh fabric is introduced between non-crimped layers of unidirectional reinforcing fibers to produce a preform for use in liquid-molding processes to produce composite materials. Interlayer material remains as a separate phase from matrix resin after infusion, and curing of the preform provides increased impact resistance by increasing the amount of energy required to propagate localized fractures due to impact. Constructions having the interlayer materials melt-bonded to the reinforcing fibers demonstrate improved mechanical performance through improved fiber alignment compared to other fabrication and preforming methods.

Abstract: Carbon nanotube interlayer assemblies, methods of manufacturing carbon nanotube interlayer assemblies, and methods of manufacturing composite parts with carbon nanotube interlayer assemblies are disclosed herein. In one embodiment, a method of manufacturing a composite structure in accordance with an embodiment of the invention includes producing a plurality of carbon nanotubes on one or both sides of a substrate, and attaching the substrate to a first fiber layer. The method can further include positioning a second fiber layer adjacent to the first fiber layer to position the plurality of carbon nanotubes between the first and second fiber layers. The method can additionally include infusing the first and second fiber layers with resin, and curing the resin. In one embodiment, the carbon nanotube substrate can be attached to the first fiber layer by melt-bonding. In another embodiment, the carbon nanotube substrate can be attached to the first fiber layer with stitches.

Abstract: A non-crimped, unidirectional fabric. The fabric includes a plurality of non-crimped, unidirectional fibers arranged parallel to one another. Weft fibers are arranged perpendicular to the non-crimped, unidirectional fibers. Warp fibers are arranged parallel to the non-crimped, unidirectional fibers. The weft fibers are woven around the non-crimped, unidirectional fibers and around the warp fibers without crimping the unidirectional fibers. A non-woven thermoplastic fabric is secured, such as by melt bonding, to the non-crimped unidirectional fibers to act as a toughening layer and improve the impact resistance of the fabric after it is molded into a part.

Abstract: Materials and methods are provided for producing preform materials for impact-resistant composite materials suitable for liquid molding. An interlayer comprising a spunbonded, spunlaced, or mesh fabric is introduced between non-crimped layers of unidirectional reinforcing fibers to produce a preform for use in liquid-molding processes to produce composite materials. Interlayer material remains as a separate phase from matrix resin after infusion, and curing of the preform provides increased impact resistance by increasing the amount of energy required to propagate localized fractures due to impact. Constructions having the interlayer materials melt-bonded to the reinforcing fibers demonstrate improved mechanical preformance through improved fiber alignment compared to other fabrication and preforming methods.

Abstract: A composite material comprising a flexible jacket covering a roving of fibers which have been impregnated with a metal powder is described. The flexible jacket allows the material to be handled easily and to be weaved, knitted or braided into the shape or form desired. The jacket is made from a thermoplastic which decomposes or is otherwise fugitive during the processing of the woven form in which the metal is melted to consolidate the form into a finished part.

Abstract: A honeycomb sandwich panel modified by the controlled incursion of a foaming fiber-filled adhesive into the upper region of the honeycomb provides a panel having increased durability when the upper surface is subjected to localized compressive loads.

Abstract: A combination of a thin upper honeycomb core plus a lower honeycomb core of equal or lower density than the upper core united by only a thin light weight interlayer within two outer skins provides a low weight hybrid panel with increased durability when the upper surface is subjected to localized compressive loads.