Abstract: Gel coating of thermoplastic particles, such as polyimide particles, with a polyketone or polyvinyl alcohol gel, and applying the gel coated particles to reinforcement, e.g. carbon, fibers to form a pre-preg. Such gel coated thermoplastic particles can be mixed with a thermosetting resin to form a pre-preg, which can be cured at elevated temperatures to form a composite having damage tolerance characteristics. The gel coating is applied to the thermoplastic particles by contacting such particles with a polymerizable material such as acetone in a weakly acidic solution to cause the acetone to undergo tautomerism, and in the presence of a polymerization promoter or catalyst, preferably certain anionic surfactants such as sulfated ammonium salts, to convert the tautomer to polyacetone gel of low molecular weight, which coats or encapsulates the thermoplastic particles.

Abstract: A process for producing ultra-high molecular weight polyamide fibers by thermal post condensation in the solid phase in the presence of catalysts of normally viscous polyamide fibers below their melting point in the absence of oxygen wherein the fibers have extremely high relative solution viscosities.

Abstract: A process for making 2D and 3D carbon-carbon composites having a combined high crystallinity, high strength, high modulus and high thermal and electrical conductivity. High-modulus/high-strength mesophase derived carbon fibers are woven into a suitable cloth. Layers of this easily graphitizible woven cloth are infiltrated with carbon material to form green composites. The carbonized composite is then impregnated several times with pitch by covering the composite with hot pitch under pressure. The composites are given a heat treatment between each impregnant step to crack up the infiltrated carbon and allow additional pitch to enter the microstructure during the next impregnation cycle. The impregnated composites are then given a final heat treatment in the range 2500.degree. to 3100.degree. C. to fully graphitize the fibers and the matrix carbon. The composites are then infiltrated with pyrolytic carbon by chemical vapor deposition in the range 1000.degree. C. to 1300.degree. C. at a reduced. pressure.

Abstract: A method of fabricating a preform for use in a resin transfer molding process. The method includes the steps of locating a transport member on a mandrel. A dry fiber layer is filament wound about the mandrel over the transport member. A tackifier is applied to the dry fiber layer at least in the area of the transport member. The filament wound dry fiber layer is cut about the transport member to provide a preform thereon. The preform is transported to a resin transfer mold by use of the transport member. The preform then is resin transfer molded in the mold.

Abstract: A blanket is disclosed for an extended nip press. The blanket includes a woven base having a first plurality of filaments which are disposed in a machine direction. The first plurality of filaments have a modulus of elasticity which permits flexing of the blanket during movement of the blanket through the extended nip press. The base also includes a second plurality of filaments woven together with the first plurality of filaments and disposed in a cross-machine direction. The second plurality of filaments have a modulus of elasticity which is higher than the modulus of elasticity of the first plurality of filaments for inhibiting flexing of the blanket in a cross-machine direction. Thermo-setting resin is applied to the base such that the resin is reinforced by the base. The resin defines a plurality of vents for permitting the escape of water in the liquid and vapor phase away from the extended nip press during use thereof.

Abstract: A method of forming a rigid composite varishaped product by knitting an integral fabric piece in the desired shape and impregnating the knitted piece with a selected settable impregnate which is then set; the products made from the method including the intermediate knitted products and the process for making the intermediate product and the knitting program for directing the needles of the knitting machine on which the intermediate product is made.

Abstract: A method of producing fiber reinforced plastic moldings.

Abstract: The process for the forming of a covering element particularly for vehicle interiors consists in associating at a preset pressure, a wooden plate-like element with a malleable support defined by at least one layer made of a fabric impregnated with a product based on epoxy resin: subsequently, during the application of the pressure, the assembly is heated to a preset temperature to give the wooden plate-like element and the support the pre-required configuration; the covering element obtained with the above process includes a layer of wooden material (2) associated with a support (3) which is defined by at least one layer of fabric impregnated by a product based on epoxy resin.

Abstract: A composite beam having a constant stress geometry is provided wherein a varying fiber content in a fiber impregnated resin is employed across the beam's cross section to cause the neutral axis of the beam to shift toward the compressive side. The design provides the maximum deflection in the direction of the load before compressive failure occurs for a given size and shaped beam of equivalent stiffness.

Abstract: The present invention contemplates a method of continuously forming a layered composite material into a rigid structure as the material is moved from an upstream location to a downstream location. The uncured layered composite material is pulled from a supply at the upstream location through a forming die to form the material into a structural member having a desired shape. The member is moved downstream into a heating die where it is at least partially cured. After it leaves the heating die it is cooled and continues to move downstream where it is cut into suitable lengths. The cooling can be accomplished by a cooling die located downstream from the heating die. A liner is provided within the dies having the same shape as the structural member through which the structural member slides as it moves in the downstream location.

Abstract: A method of forming a hose assembly (10) of the type adapted for carrying fuels and other corrosive fluids. An inner liner (16) of a fluorocarbon material is extruded. The inner liner (16) is then passed through a reservoir containing a dispersion including a fluorocarbon polymer material and a fluid. Glass fibers are then braided about the exterior of the inner liner (16) to form a braided layer (18) having the dispersion thereabout such that the dispersion penetrates the interstitial spaces of the braided layer (18). Subsequently, the assembly (10) is heated to remove the fluid. The assembly is then sintered to cure the fluorocarbon polymer material into a coating dispersed throughout the braided layer (18) and about the inner liner (16).

Abstract: A method for producing a fiber reinforced plastic rod having ribs on its surface by impregnating a reinforcing material which has continuous long fiber bundles with an uncured liquid resin. A rib forming member is separately prepared by impregnating a fiber bundle reinforcing material with an uncured liquid resin. A fiber reinforced plastic rod is formed by helically applying the rib forming member to the surface of the substrate forming member and together curing the two members into an integral body. A fiber reinforced plastic rod, prepared in accordance with this method, is also described.

Abstract: The present invention is a wax-based material for use in the lost wax process where the wax must be capable of withstanding temperatures of up to 350.degree. F., the wax-based material including: (a) a high temperature brittle wax; (b) about 5-30 wt % organic plasticizer including polyfunctional amines and alcohol amines and (c) about 5-10 wt % paraffin wax.

Abstract: A method of finishing carbon fibers with phenolic triazine to promote adhesing of the carbon fibers with a resin matrix to retain up to 92% of the room temperature dry strength at a temperature of 500.degree. F.

Abstract: A continuous process for the manufacture of friction units includes the steps of impregnating a plurality of strands of reinforcing fibers with a thermoplastic material, pulling the impregnated strands of reinforcing fibers through a composite forming die for forming a body having the peripheral configuration of the friction units, and selectively cutting the body into a plurality of the friction units.

Abstract: A double wall tank for the storage of liquids is manufactured from a rigid single wall inenr tank by forming a mixture of an internal lubricating agent and a curable synthetic resin and applying over the inner tank exerior surface the mixture of the lubricating agent and the curable synthetic resin to form, when cured, a substantially rigid outer sheath that is substantially fluid tight and that resists bonding to the inner tank.

Abstract: A method of manufacturing a composite material formed of a fibrous reinforcement and a silica based ceramic or vitro-ceramic matrix. The method includes impregnating the fibrous reinforcement by means of a sol-gel process wherein premature crystallization of the matrix obtained from the sol is hindered by addition to the sol of a crystallization retarding agent, and hot pressing the resulting material. The composite material formed has a residual porosity without the addition of nucleating agents of about less than 10%.

Abstract: A modular mold system for making molds in a range of incrementally different sizes is provided as is a method for using that system in the manufacture of containers. The mold system includes corner elements, edge angle elements and spacer elements which can be interlocked together through connecting means to form a mold for a container. The boundaries of each mold element are defined by straight lines meeting at right angles and each mold element has at least one common dimension with every other element. The mold system is particularly adapted for use in making fiberglass reinforced products such as insulated containers having an inner shell and an outer shell with insulation between the shells.

Abstract: In the manufacture of an in-line cored pultruded profile, filler is bonded with polyester or methacrylate type resin and enclosed in fiberglass, carbon or aramid fiber cloth. The cloth is preformed to replicate the desired profile shape by means of a pre-die former and the external surface of a hollow duct. Filler is delivered into the interior of the duct by a variable output venturi blower. Precise distribution of packing is effected by the internal configuration of the duct and the creation of a raised moving wall when non-foaming resin is used. Precise configuration of ducts can be achieved by fashioning from reinforced cloth. Adjustable start drums provide time and labor saving benefits. Complete resin wet through using either foaming or non-foaming resin ensures exellent filler bonding and surface finish.

Abstract: A multi-dimensional (e.g., 3D braided) preform formed of reinforcement strands or filaments is rigidized by impregnating the preform with a resin solution (e.g., silicone resin solution), curing the resin to impart a selected shape to the preform and then heating the shaped preform to convert the cured resin to inorganic solids (e.g., silica solids) so dispersed in an effective amount between the strands as to rigidize the preform. The rigidized preform is then infiltrated with an inorganic matrix (e.g., a ceramic material) to form a composite article.

Abstract: A process for preparing a postformable composite article of a heat curable thermosetting polymer having a substantial length and a non-trivial uniform cross-sectional shape. The process includes controlling the pull rate and the temperature of the heating and cooling sections of the die in response to the viscosity and the cure kinetics of the thermosetting polymer composition and (2) the non-trivial shape of the article.

Abstract: Extruded thermoplastic members, particularly structural members, are reinforced by longitudinally extending pre-stressed elements, such as filaments or matting. The elements, while under tension, are drawn into an extrusion crosshead die forming the thermoplasatic member. The elements are fully imbedded within the thermoplastic material while under tension and curing of the thermoplastic material, and final curing of the tensioned reinforcing elements, if a thermosetting resin impregnated element is used, occurs while the elements are under tension, the material of the member and the elements intimately bond and the tension forces within the elements reinforce the member at the desired locations. The forming of the reinforced member is a continuous operation.

Abstract: A process for preparation of a carbon fiber composite reinforced carbonaceous material characterized in that using carbon fibers or the raw material fibers of the carbon fibers as the base material, the surfaces of said base material fibers even to the surface of the single fiber are uniformly and completely coated with dormant mesophase pitch and/or isotropic pitch, and after said base material has been molded, the resulting product is subjected to carbonization treatment or graphitization treatment.

Abstract: A molded article is produced by metathesis polymerization of a mixture containing at least one metathesis polymerizable monomer, a metathesis polymerization catalyst and an organic or inorganic filler material which has been treated with a vinyl-substituted silane coupler having at least one hydrolyzable group in addition to the vinyl group.

Abstract: Novel ceramic filamentary micro-tubular materials are described. An entirely, fluid-phase method has been devised for producing such interwoven ceramic filamentary tubular materials. The process depends for its success the ability to generate a three-dimensional random weave of ceramic tubes, with diameters in the range of about 0.01 to 2.0 microns, by forming carbon filaments by catalytic decomposition of a hydrocarbon feed, coating the filaments with a ceramic coating and then oxidizing the coated filaments to remove the carbon core leaving behind hollow ceramic micro-tubular filaments. The ceramic micro-tubular materials may be free-standing porous structures and may have a variety of uses as thermal insulators, catalyst supports, superconductor supports, filters or as reinforcements for composites.

Abstract: A twisted FRP structure having sufficient strength and flexibility is produced by providing a rod member disposed centrally and twist a plurality of side strands twisted around the rod member in the same direction at a predetermined pitch. At least the side strand includes a composite strand having an FRP element from by impregnating fibers with an uncured thermosetting resin and a thermoplastic coating on such FRP element, the thermosetting resin being cured after the side strands are twisted around the rod member. The twisting pitch is not less than 25 times the outside diameter of the FRP element in the side strand.

Abstract: A method of making a heat-resistant paper container which comprises a bottomed seamless press-molded body comprising a laminate of a paper substrate having an elongation of at least 1.5% in the longitudinal direction and an elongation of at least 4.5% in the lateral direction and a coating layer of a hiding pigment formed on both the surfaces of the paper substrate, wherein the amount coated of the hiding pigment is 1 to 50 g/m.sup.2, the binder in the coating layer is a thermosetting resin binder and the binder is present in the coating layer at a weight ratio R.sub.P satisfying the following condition:R.sub.P =k.multidot.O.sub.A .multidot.d.sub.Rwherein O.sub.A stands for the oil absorption (ml/100 g) of the hiding pigment, d.sub.A stands for the density (g/ml) of the binder, and k is a number of from 0.005 to 0.2.

Abstract: Preforms for molding processes such as resin transfer molding processes are prepared by melting a solid, non-sintering, thermoplastic-like resinous compound on the surface of a substrate material. After cooling, assembling one or more plies of the coated substrate material into the desired shape; heating the shaped substrate material to a temperature above the melting temperature of the resinous compound and subsequently cooling to a temperature below the melting point of the resinous compound.

Abstract: A process for making a carbon-carbon composite having a combination of high crystallinity, high strength, high modulus and high thermal and electrical conductivity. High-modulus/high-strength mesophase derived carbon fibers are woven into a suitable cloth. Layers of this easily graphitizable woven cloth are covered with petroleum or coal tar pitch and pressed at a temperature a few degrees above the softening point of the pitch to form a green laminated composite. The green composite is restrained in a suitable fixture and heated slowly to carbonize the pitch binder. The carbonized composite is then impregnated several times with pitch by covering the composite with hot pitch under pressure. The composites are given a heat treatment between each impregnation step to crack up the infiltrated carbon and allow additional pitch to enter the microstructure during the next impregnation cycle. The impregnated composites are then given a final heat treatment in the range 2500.degree. to 3000.degree. C.

Abstract: A process for continuously forming reinforced articles (24) which includes producing a reinforcing material (13) having a plurality of superimposed layers (1-6), stitching together said layers (1-6), wetting said reinforcing material (13) with a matrix material (7, 8 or 19), forming the wetted reinforcing material and curing or consolidating the matrix material. Each layer (1-6) of the reinforcing material (13) includes a plurality of unidirectional non-woven yarns or threads (10) laid side-by-side, the yarns or threads (10) in at least some of the different layers (1-6) extending in different directions. Forming of the wetted reinforcing material may be effected by moulding, pultrusion or by wrapping wetted reinforcing material around a mandrel or former (25).

Abstract: Binder-impregnated carbon fiber rovings and the like, which are sticky and difficult to handle, are stacked to form modules that are packed in resinous bags under vacuum, and are then shaped to desired dimensions and densities without employing conventional molds, but simply by placing them in the confines of jigs or ruler frames and then releasing them from vacuum and expanding them to the desired dimensions. They are thereafter subjected to heat treatments to provide high temperature resistant carbon fiber-reinforced carbon or graphite modules which work, for example, as thermal insulation and refractory walls in high temperature heating furnaces.

Abstract: A method of making a double wall tank from a single wall inner tank. A mixture of an internal lubricating agent and a curable synthetic resin is formed and applied over an exterior portion of the tank which when cured forms a rigid outer sheath that is fluid tight and resists bonding to the inner tank.

Abstract: The process makes use of a lost core of polystyrene, on which are wrapped and compacted, in successive stages, various sheets or mats of carbon fibre, of known type; a first compaction is effected in an autoclave after having sealingly wrapped the core, before lamination of the carbon fibre layers, in a first polythene envelope, and after having sealingly wrapped the partly finished product constituted by the core wrapped in the first polythene envelope and some of the carbon fibre sheet or mat in a second polythene envelope, by creation of a vacuum within the interior of the second envelope, while maintaining the interior of the first envelope in communication with the outside of the second envelope; a second compaction, after removal of the second envelope, following lamination of further sheets or mats and possible mounting of metal inserts on the core and insertion of the partly finished product thus obtained between a pair of mould halves, is effected in an autoclave by wrapping the two mould halves, pre

Abstract: The disclosure herein describes a method for producing a structure, more particularly a wooden structure, in the surface of a hardened fibreboard, especially a medium-density fibreboard; it comprises the steps of: applying a resin-water mix to the surface of the fibreboard on one or both sides to soften and penetrate into the surface of the fibreboard; and pressing the fibreboard with a short-cycle press, under the action of pressure and heat, and using a structured pressure-plate. The water-part of the resin-water mix is caused to evaporate and the resin-part to cure, whereas the structure of the pressure-plate is moulded into the surface of the fibreboard.

Abstract: Fiber reinforced plastic tubing is formed by an innermost layer of braided strands that include longitudinal stud fill strands within the braid, a second layer of longitudinal strands, and a third layer of braided strands, all thoroughly encased in a monolithic mass of plastic matrix material that is not, itself, divided into layers. The tube is fabricated on a continuous basis by winding two sets of strands in opposite directions on a mandrel and braiding the two sets with each other and with stud fill strands that prevent that first layer of braid from stretching longitudinally and thereby tightening immovably on the mandrel. The strands are braided dry but are wetted with liquid plastic matrix material as the braid is compacted on the mandrel.

Abstract: A process for forming flat plate ballistic resistant composites which includes impregnating a low-alkali magnesia-aluminum-silicate glass fiber woven roving with an impregnating composition. The impregnating composition includes a resin solution of a polyester resin in a polymerizable monomeric solvent a free radical catalyst and optionally, a thickening agent and further optionally a flame retardant material. The impregnated woven roving is cured in a molding unit at a temperature of about 225.degree.-255.degree. F. for a sufficient period of time and at a sufficient pressure to allow the impregnated woven roving to substantially conform to the mold unit. The temperature and pressure used are sufficient to maintain the exothermic temperature at about 300.degree. F. or below and to catalytically crosslink the polyester resin and monomeric solvent.

Abstract: Staple fibers having a crimp frequency in the range of 3 to 6 crimps per centimeter are made by a process including a co-crimping step in which conductive and nonconductive filaments are crimped together.

Abstract: Low density fibrous mats formed from fibres and thermosetting and thermoplastic binders, transformed by moulding at elevated temperatures are used for the production of mouldings. Such fibrous mats are produced in that a mixture of fibres and binders is spread out to form a fleece and the latter is compressed or compacted to a mat at high temperature. For the planned influencing of the characteristics of the moulding, while simultaneously reducing the binder requirement and the density, it is proposed that the fibrous mat or blanks thereof is passed through a pair of rollers with polished surfaces and by means of at least one roller binder is applied from the aqueous phase to the side of the fibrous mat facing the same under pressure action and that the fibrous mat is passed through the roller pair at a speed lower than the circumferential speed thereof and following onto the roller pair is passed through a drying zone.

Abstract: Preforms for molding processes such as resin transfer molding processes are prepared by melting a solid, non-sintering, thermoplastic-like resinous compound on the surface of a substrate material; after cooling, assembling one or more plies of the coated substrate material into the desired shape; heating the thus shaped substrate material to a temperature above the melting temperature of resinous compound and subsequently cooling to a temperature below the melting point of the resinous compound.

Abstract: A process for producing improved gypsum models and molds of high duplication accuracy is provided. In the process, bundles of carbon fibers of specified length and amount having a sizing agent deposited thereon are treated to remove the sizing agent from the carbon fibers which are then separated into single fibers in water. A major part of hemihydrate gypsum (CaSO.sub.4.1/2H.sub.2 O) powder is then added to the carbon fibers dispersed in water to obtain a gypsum slurry having the carbon fibers uniformly dispersed therein. The slurry is then cast to obtain the models or molds.

Abstract: Structures of inorganic fibers which may contain inorganic particles, flakes or powders, are prepared by adding aqueous silicone resin emulsions containing curing catalysts and emulsifiers to the fiber material, shaping the treated fiber material, and subsequently curing the silicone resin, in which salts or chelates of trivalent iron are employed as the curing catalysts. Iron (III) acetylacetonate is preferably employed as the curing catalyst. The structures are preferably produced in a continuous process in which the aqueous silicone resin emulsion is sprayed onto the fiber material, then the fiber material is compacted to the desired bulk density and the silicone resin is cured by contacting the compacted fiber material with hot gases. Curing of the silicone resin is preferably carried out at a temperature of from 150.degree. to 300.degree. C. over a period of from 5 to 8 minutes.

Abstract: An oxidation process for stabilization of pitch-based matrices in the fabrication of carbon-carbon composites. By oxidizing a fiber preform impregnated with petroleum-derived mesophase pitch at temperatures in the range of 190.degree. to 300.degree. C. for periods of the order of ten hours, the matrix is fixed in place within the preform so that softening, bloating, and expulsion of the matrix are avoided when the body is carbonized. The invention can also be practiced to increase the carbon yield upon carbonization. Sufficient access porosity must exist in the matrix to permit oxidation throughout the composite body; this is normally formed in a preform due to the mismatch in thermal expansivities of fiber and matrix. Also, the softening point of the pitch must be above the oxidation temperature; this need can be met for most mesophase pitches.

Abstract: A process for the manufacture of a stiff permeable sheet-like fibrous structure which includes forming a web with 20% to 60% single fibres having a high modulus of elasticity (as herein defined) and between 7 and 50 millimeters long, and 40% to 60% by weight of a wholly or substantially unconsolidated particulate plastics material, and then treating the web by heating to melt the plastics material and passing it between a pair of nip rollers so that the plastics material can flow and wet out the fibres, the nip between the rollers being set to a dimension less than the thickness of the unconsolidated web and greater than that of the web if it were to be fully consolidated, and allowing the web to expand and remain substantially permeable after passing through the rollers.

Abstract: A composite implant prosthesis comprising a core constructed from a plurality of carbon fibers, a first casing formed from a braided sheath of carbon fibers and a second casing enclosing the core and first casing to define an outer surface contour for the composite implant prosthesis. The method for constructing the composite implant prosthesis includes the steps of pultruding the core from a polymer impregnated tow, braiding the first casing to the pultruded core and applying the second casing thereto. The pultruding and braiding steps are performed in a continuous process while the second casing is applied to a discrete element formed from the core.

Abstract: Process for producing a fiber reinforced plastics linear material like a tension member for optical communication cables. A groove capable of accomodating an optical fiber is formed in the outer surface of the tension member. In accordance with the conventional method, the groove is necessarily formed in parallel along the axial direction of the tension member and, therefore, if the tension member is bent in the state that the optical fiber is placed in the groove, a force due to bending is applied directly to the optical fiber and the transmission loss of the optical fiber is increased.

Abstract: A novel isotropically reinforced microcomposite is described. An entirely fluid-phase method has been devised for producing the net-shape filamentary structures. The process depends for its success on the ability to generate in situ, within a shaped mold, a three-dimensional random weave of carbon filaments by catalytic decomposition of a hydrocarbon feed. Almost any desired filament filler matrix combination can be produced by utilizing chemical vapor deposition to modify the surface and bulk properties of the filamentary structure. Infiltration of filler matrix materials can be achieved by adaptation of existing materials technologies.

Abstract: A process for increasing the damage tolerance in thermoset composites without loss of processibility or mechanical properties of the thermoset, by controlled solubility of a thermoplastic filler in the base thermoset. The process includes mixing spherical particles of a selected thermoplastic, such as polyimide, of particle size ranging from about 10 to 80 microns, with a hot thermoset resin, such as a bismaleimide, to form a uniform dispersion of the resin mixture, employing about 5 to about 40% of the thermoplastic by weight of the mixture of the two resins. The particles of thermoplastic are non-agglomerating and insoluble in the resin mixture. The hot resin dispersion is then applied to fiber reinforcement, such as carbon fiber tapes, to form pre-pregs. Upon curing the thermoset at elevated temperature, the thermoplastic particles dissolve in the thermoset resin, forming a composite with no definable boundary interfaces between the thermoplastic and thermosetting resins.

Abstract: A method for making an Airspring and Sleeve that each have a chamber portion and rolling lobe portion reinforced with successive layers of embedded cord by winding cord in one layer at opposite helical angles from cord of a second successive layer and winding cord at inconstant helical angles in an annular band portion of at least one of the sleeve portions.

Abstract: A process for producing a prepreg and a process for producing a laminated sheet therefrom are disclosed, the process for producing a prepreg comprising impregnating a fibrous base with an impregnating resin composition essentially comprising (A.sub.1) a room temperature liquid epoxy resin, (A.sub.2) an epoxy resin curing agent, (B.sub.1) a resin containing a polymerizable unsaturated group, (B.sub.2) a room temperature liquid polymerizable vinyl monomer, and (B.sub.3) a polymerization initiator and containing no solvent other than said polymerizable vinyl monomer (B.sub.2), to obtain an impregnated base, and then removing the polymerizable vinyl monomer present in said impregnated base and converting the resin components to the B-stage. The prepreg is tack-free and soft, and the laminated sheet obtained therefrom has improved metal foil peel strength and interlaminar peel strength.

Abstract: An improved process for the high speed production of structural preforms and molding the preform to produce a product having desired and predetermined fiber directionality and distribution. Continuous strand glass fiber is directly applied to a preform screen along with a resinous binder material. The fiber/binder composite preform is cured. The cured composite preform is transferred to a mold where the composite is injected with a resin and thereafter cured in the mold.