Abstract: A void filler material includes a ceramic rod and a fibrous overwrap. The void filler material may be used in a ceramic matrix composite. The method of making the ceramic matrix composite includes inserting the void filler material in voids of a preform and depositing a ceramic matrix on the preform and the void filler material using chemical vapor infiltration.

Abstract: A method of producing a ceramic matrix composite including a protective ceramic coating thereon comprises applying a surface slurry onto an outer surface of an impregnated fiber preform. The surface slurry includes particulate ceramic solids dispersed in a flowable preceramic polymer comprising silicon, and the impregnated fiber preform comprises a framework of ceramic fibers loaded with particulate matter. The flowable preceramic polymer is cured, thereby forming on the outer surface a composite layer comprising a cured preceramic polymer with the particulate ceramic solids dispersed therein. The cured preceramic polymer is then pyrolyzed to form a porous ceramic layer comprising silicon carbide, and the impregnated fiber preform and the porous ceramic layer are infiltrated with a molten material comprising silicon. After infiltration, the molten material is cooled to form a ceramic matrix composite body with a protective ceramic coating thereon.

Abstract: A method of fabricating an airfoil fairing for a vane arc segment includes providing a mandrel that necks down through a mandrel neck portion, providing fiber plies around the mandrel to form a tube that defines at least a portion of an airfoil profile of an airfoil section of an airfoil fairing, the fiber plies following the mandrel neck portion such that the tube has a corresponding tube neck portion that necks down to a collar, and removing the mandrel from the tube.

Abstract: A flame or heat flux protective coating composition, which includes a dispersion of fiberglass, hollow glass spheres, or a combination of both in silicone. A flame or heat flux protective sheet, which includes hollow glass spheres dispersed in silicone in a sheet form or fiberglass and silicone in a sheet form, wherein the fiberglass is dispersed in the silicone or the fiberglass is a woven cloth coated with the silicone is also presented. Articles incorporating the flame or heat flux protective coating or sheet form and methods for coating an article with the flame or heat flux protective coating composition are also presented.

Abstract: A multi-layer, fluid transmissive structure is provided that comprises first and second fiber layers each comprising a plurality of polymeric fibers bonded to each other at spaced apart contact points. The polymeric fibers of these fiber layers have diameters greater than one micron and collectively define interconnected interstitial spaces providing tortuous fluid flow paths through the first and second fiber layers. The structure also comprises a plurality of nanofibers disposed intermediate at least a portion of the first fiber layer and at least a portion of the second fiber layer.

Abstract: Novel composite materials are provided consisting of a substrate based on fibers of natural, mineral or vegetable origin, and of a mixture formed from a matrix of water-based resin and an expanding agent. The nature and the proportions of the various elements constituting these novel composite materials is also provided. A method of manufacture for making these novel composite materials starting from the constituent elements and the characteristics of the different steps of said method is also provided.

Abstract: A ceramic composite material is comprised of a fabric of fibers of an inorganic substance; and a matrix for combining the fibers. The matrix consists essentially of a ceramic. The matrix is formed by burying the fabric in a mixture of a powder of carbon, a powder of silicon and a medium including an organic solvent, producing an oscillation in the mixture to impregnate the fabric with the mixture, and calcining the fabric impregnated with the mixture.

Abstract: A tackifier composition includes a carrier solvent, a resin material, and an inorganic filler. The tackifier composition may be deposited onto at least a portion of a woven fiber structure and then dried to remove the carrier solvent. The dried woven fiber structure may then be formed into a preform.

Abstract: A protective jacketing-insulation composite structure and method is provided for inhibiting the corrosion of a pipeline. The method includes forming a porous-insulation into an elongated-arcuate-shape, applying a sodium silicate solution layer to the insulation and at least partially within the pores thereof, permitting the sodium silicate solution layer to set to a threshold amount, adhering an outer facing to the sodium silicate solution layer after the permitting step is accomplished, installing the insulation and facing to the outer surface of a pipeline, and sealing any exposed edges or seams that may exist between multiple installed products. A structure such as made from this method can have a release layer and contact adhesive.

Abstract: This invention concerns with a composite film or a layered product having high transparency, excellent resistance to heat and excellent dimensional stability, useful in the manufacturing of electronic display devices, photovoltaic devices, lighting devices, automotive windshields and lights, and safety and armored windows.

Abstract: The invention relates to a new binder composition which is particularly suitable for the manufacture of composite materials utilizing such new binder composition in the required nonwoven materials. Composite materials using such new binder composition in their nonwoven part are suitable, in particular, for composites materials for interior construction, for linings, floor coverings, and for the manufacture of furniture and similar products.

Abstract: A three-dimensional composite reinforcement, a three-dimensionally reinforced multifunctional nanocomposite, and methods of manufacture of each are disclosed. The three dimensional reinforcement comprises a two dimensional fiber cloth upon which carbon nanotubes have been grown, approximately perpendicular to the plane of the fiber cloth. The nanocomposite comprises the three-dimensional reinforcement and a surrounding matrix material. Examples illustrate improvements in the through-thickness mechanical, thermal, and electrical properties of the nanocomposite, in addition to substantial improvements in geometrical stability upon temperature changes and vibrational damping, compared to baseline composites reinforced with the two-dimensional fiber cloth alone.

Abstract: A ceramic matrix composite with a ceramic matrix and a gradient layering of coating on ceramic fibers. The coating typically improves the performance of the composite in one direction while degrading it in another direction. For a SiC-SiC ceramic matrix composite, a BN coating is layered in a gradient fashion or in a step-wise fashion in different regions of the article comprising the ceramic. The BN coating thickness is applied over the ceramic fibers to produce varying desired physical properties by varying the coating thickness within differing regions of the composite, thereby tailoring the strength of the composite in the different regions. The coating may be applied as a single layer as a multi-layer coating to enhance the performance of the coating as the ceramic matrix is formed or infiltrated from precursor materials into a preform of the ceramic fibers.

Abstract: An article such as a fan blade of a turbofan engine comprises a core made up of components at least some of which comprise packs of rods embedded in a resin matrix material. The rods extend in the span-wise direction of the blade to resist centrifugal forces imposed on the blade during operation. The core is encased in a skin formed from preforms which may comprise fabric reinforcements.

Abstract: A composite blade (26) comprises a three-dimensional arrangement of reinforcing fibres (58) and a matrix material (60) infiltrated around the three-dimensional arrangement of woven reinforcing fibres (60). The three-dimensional arrangement of woven reinforcing fibres (58) defines a plurality of cavities (56) within the aerofoil (28). The composite blade (26) comprises an aerofoil portion (38) and a root portion (36). The aerofoil portion (38) comprises a leading edge (44), a trailing edge (46), a concave pressure surface wall (50), a convex suction surface wall (52) and a tip (48). The aerofoil portion (36) comprises a plurality of webs (54) extending between, and being secured to, the concave pressure surface wall (50) and the convex suction surface wall (52) to produce a Warren girder structure. The three-dimensional arrangement of woven reinforcing fibres (58) are arranged to produce the concave pressure surface wall (50), the convex suction surface wall (52) and the plurality of webs (54).

Abstract: A composite resin molded product has a molded product body made of a resin and a fiber sheet material inserted on the surface of the molded product body. The fiber sheet material is formed of a knitted fabric, and the rear surface of the knitted fabric faces the molded product. The surfaces of fiber yarns of the knitted fabric are integrated with the molded product body by melting and solidifying.

Abstract: A tackifier composition includes a carrier solvent, a resin material, and an inorganic filler. The tackifier composition may be deposited onto at least a portion of a woven fiber structure and then dried to remove the carrier solvent. The dried woven fiber structure may then be formed into a preform.

Abstract: A self-healing composite material comprising a fibre-reinforced polymeric matrix, wherein the polymeric matrix comprises a thermosetting polymer and a thermoplastic polymer.

Abstract: A production process which comprises a preform formation step of forming a fiber preform made of silicon carbide short fibers having heat resistance of 1000° C. or greater; a sol-gel preparation step of preparing a sol-gel solution containing a heat resistant compound having heat resistance of 1000° C. or greater; an impregnation-drying-calcination step of impregnating the fiber preform with the sol-gel solution, followed by drying and calcining; and a crystallization step of crystallizing the fiber preform after impregnation, drying and calcination.

Abstract: An impregnated fibrous veil comprises a nonwoven fibrous veil including a prebinder and reinforcing fibers. The fibers are selected from a group consisting of glass fibers, ceramic fibers and mixtures thereof. The nonwoven fibrous veil has at least one face impregnated with a surface finish formulation. The surface finish formulation includes about 50 to about 95 weight percent filler, about 5 to about 50 weight percent binder and about 0 to about 10 percent optical brightener.

Abstract: A method of making a smooth surfaced, fiber reinforced ceramic matrix composite includes the steps of providing a fiber preform, the preform having a surface containing voids; placing fibers into the voids; coating the preform fibers and the void fibers with a coating material to create a weak interface; and infiltrating the coated fibers with a matrix material to infill the voids and preform, and form strongly bonded networks within the voids. Alternatively, the resulting smooth surfaced, fiber reinforced ceramic matrix composite may include, in addition to the first coating material on the preform fibers and the void fibers and the matrix material within the coated fibers and the preform to infill the voids and preform, a second coating material on the preform fibers and the void fibers, creating a second coating of substantially uniform thickness on the fibers and forming strongly bonded networks within the voids.

Abstract: An impregnated fibrous veil comprises a nonwoven fibrous veil including a prebinder and reinforcing fibers. The reinforcing fibers are selected from a group consisting of glass fibers, ceramic fibers and mixtures thereof. The nonwoven fibrous veil has at least one face impregnated with a surface finish formulation. The surface finish formulation includes about 80 to about 98 weight percent filler, about 2 to about 20 weight percent binder and about 0 to about 1 weight percent optical brightener.

Abstract: Compositions comprising maleinized imide polymer and ?,?-ethylenically unsaturated carboxylic, the polymer selected from the group consisting of butadiene homopolymer, butadiene copolymers, isoprene homopolymer, isoprene copolymers. and poly(maleic anhydride-co-alkenyl benzenes), are disclosed. Maleinized imide resin, optionally in solution and optionally comprising metallic salt of ?,?-ethylenically unsaturated carboxylic acid, is used to treat fabric and thereby improve fabric to rubber adhesion. The resultant treated fabric and fabric-rubber composite are also disclosed.

Abstract: A reinforcement fabric includes a first layer of collimated continuous fibers, a second layer selected from a group consisting of veil, continuous filament mat, chopped strand mat, direct chopped mat, direct continuous mat, collimated continuous fibers, woven fabric, non-woven fabric, scrim and combinations thereof as well as a surface adhesive that adheres the first and second layers together. The surface adhesive is selected from a group consisting of hot melt adhesive and web bonded adhesive. The surface adhesive has a melt flow index range of about 5 to about 500 at room temperature and about 900 to about 1300 at application temperature. A method is also provided for the production of the reinforcement fabric.

Abstract: A hybrid of vinyl flooring and soft cushioned carpet is provided. The hybrid flooring, which is suitable for production into tiles, utilizes woven PVC fabric that is bonded to a flexible backing. The fabric comprises woven solid color and/or multi-color yarns in order to produce different visual styles. These yarns comprise a ceramic fiber core, preferably fiberglass, onto which PVC is extruded in order to form a PVC jacket. The core provides the yarn with sufficient tensile strength so it can be woven while the PVC provides durability, resistance to wear and color. After the fabric is woven, it is sent through a tentering or curing oven which fuses the warp and fill yarns of the fabric, thereby stabilizing the fabric, preserving its integrity and preventing it from unraveling.

Abstract: A composite sheet, and a process of making the same, including cured modified urea formaldehyde reinforced by glass fibers. The modifier is an acrylonitrile-butadiene-styrene copolymer. A roofing shingle, formed by coating the composite sheet with filled asphalt, represents a major application of the composite sheet.

Abstract: The present invention is a ceramic matrix composite turbine engine component, wherein the component has a region of expected higher interlaminate stress during normal engine operation. The component includes both coated fiber tows and uncoated fiber tows arranged together into a preselected form, wherein the uncoated fiber tows are located at predetermined regions of expected high interlaminate stress. The invention further includes method of manufacturing a CMC such as a composite turbine engine component, wherein the component has a region of expected higher interlaminate stress during engine operation.

Abstract: The invention is concerned with a fibrous web for making a shaped article reinforced with fibrous webbing by impregnating the web with a liquid resin and a hardener therefor, wherein said web comprises indicating means, which indicate the impregnation of the web with said liquid resin and said hardener.

Abstract: The present invention relates to an X-ray absorbing material that can be used in medicine as well as in the manufacture of special protective clothing, protective screens, housings, protective coatings and isolation materials. In a first embodiment, the material uses as a filler a poly-dispersed mixture, segregated by kneading and containing metallic particles having a size between 10?9 and 10?3 m, wherein the particles are bonded to the surface of a textile base. The density of the material is defined by the relation qN=(0.01–0.020) qP, where qN is filler. In a second embodiment, the invention uses as a filler the above mixture, although here the particles are surrounded by the volume of a matrix made of a compound that solidifies under atmospheric pressure. The total mass of the poly-dispersed and segregated mixture is defined by the relation M=(0.05–0.

Abstract: Material from a fibre composite ceramic, constructed from a) a dense fabric or cluster of three-dimensional oriented fibres with a high thermal conductivity, b) a crystalline matrix of ?-silicon carbide, that is produced in a CVI process on the fibres, c) a matrix component of ?-silicon carbide that in a polymer infiltration and pyrolysis process is generated in pores of the fabric structure, starting from a suspension of silicon carbide powder in a polymer, and d) a further matrix component of ?-silicon carbide that is created in a CVI process in cracks and pores of the material, caused by the preceding pyrolysis process.

Abstract: A ceramic tile includes a ceramic core material and an oxide ceramic matrix composite (CMC), where the ceramic core material has at least one surface covered by the oxide CMC. The oxide CMC includes a ceramic fiber, with a cured metal oxide ceramic material impregnating the ceramic fiber. An exemplary embodiment of the ceramic tile provided as part of the invention further includes a tough low temperature cure coating (TLTC) which infiltrates the ceramic core surface before it is covered by the oxide CMC. The TLTC includes a cured ceramic powder together with a binder. The metal oxide ceramic material impregnating the ceramic fiber, and the TLTC are co-cured, meaning that neither is cured when the CMC is wrapped around a surface of the TLTC-infiltrated ceramic core, and a curing step is performed on both uncured ceramic materials at the same time.

Abstract: A fire-resistant heat insulating material excellent in resistance to heat, resistance to slag, resistance to molten iron, resistance to wear, and resistance to mechanical impulse is provided. A highly endurable heat insulating material characterized by being provided on the surface of a layer of inorganic heat insulating fibers through the medium of a coating film of surface hardening material with a flame sprayed film of a fire-resistant ceramic substance.

Abstract: A laminate of inorganic sheet and polyester resin having an overall thickness of 5 to 25 mils and having an elongation at break in both the cross direction and machine direction of at least 25%.

Abstract: A flexible insulation blanket having a smoothly surfaced, secondarily bonded, ceramic matrix composite (CMC) outer layer, and a method of producing a flexible insulation blanket having a secondarily bonded CMC layer by forming a CMC prepreg layer comprising a woven ceramic fabric layer impregnated with a pre-ceramic slurry and layering the prepreg layer with a flexible insulation blanket. The blanket and prepreg layer are then compressed such that the prepreg layer abuts a rigid smoothly surfaced plate and the ceramic material is cured by heating while under compression. Pressure is then released and the insulation is fired to sinter the ceramic material of the CMC layer.

Abstract: A coated fiber mat of improved tear strength upon dividing pieces of the coated mat and the coating is provided. The coated mat is a cured, non-woven mat including a mixture of fibers having different fiber lengths. The fibers contain a polysiloxane compound and are fixedly distributed in a binder.

Abstract: A flexible insulation blanket having a smoothly surfaced, secondarily bonded, ceramic matrix composite (CMC) outer layer, and a method of producing a flexible insulation blanket having a secondarily bonded CMC layer by forming a CMC prepreg layer comprising a woven ceramic fabric layer impregnated with a pre-ceramic slurry and layering the prepreg layer with a flexible insulation blanket. The blanket and prepreg layer are then compressed such that the prepreg layer abuts a rigid smoothly surfaced plate and the ceramic material is cured by heating while under compression. Pressure is then released and the insulation is fired to center the ceramic material of the CMC layer.

Abstract: The invention relates to a coated fiber mat of improved tear strength upon dividing pieces of the coated mat and the coating which comprises a cured, non-woven, fiber glass mat containing a polysiloxane wherein the fibers are fixedly distributed in a formaldehyde type binder containing a binder modifier which is a crosslinked styrene/acrylic polymer, and to a process for the preparation of the mat.

Abstract: A hybrid insulation material comprises of porous ceramic substrate material impregnated with nanoporous material and method of making the same is the topic of this invention. The porous substrate material has bulk density ranging from 6 to 20 lb/ft3 and is composed of about 60 to 80 wt % silica (SiO2) 20 to 40 wt % alumina (Al2O3) fibers, and with about 0.1 to 1.0 wt % boron-containing constituent as the sintering agent. The nanoporous material has density ranging from 1.0 to 10 lb/ft3 and is either fully or partially impregnated into the substrate to block the pores, resulting in substantial reduction in conduction via radiation and convention. The nanoporous material used to impregnate the fiber substrate is preferably formed from a precursor of alkoxysilane, alcohol, water, and an acid or base catalyst for silica aerogels, and from a precursor of aluminum alkoxide, alcohol, water, and an acid or base catalyst for alumina aerogels.

Abstract: Monazite or xenotime-based blanket coatings that stiffen ceramic fabrics without causing embrittlement at temperatures of at least as high as 2400° F. are provided. Methods for making the coatings are also provided. The methods comprise the synthesis of high purity, monazite and xenotime powders with the stoichiometric ratio of metal to phosphorous of about 1:1.

Abstract: A coated fiber mat of improved tear strength upon dividing pieces of the coated mat and the coating is provided. The coated mat is a cured, non-woven mat including a mixture of fibers having different fiber lengths. The fibers contain a polysiloxane compound and are fixedly distributed in a binder.

Abstract: A thermal insulating material which can be efficiently produced while the content of organic matters, such as organic fibers and/or an organic binder, is reduced to the same or lower degree as compared with the thermal insulating material used in a conventional pollution control device (e.g., catalytic converter), and which can be applied to a pollution control element (e.g., catalytic element) while avoiding, as much as possible, an unpleasant feeling to the operator. A thermal insulating material comprising a thermal insulating material body formed of a bulk material of inorganic fibers, and a coating provided on at least one surface of said thermal insulating material body.

Abstract: The invention concerns a method for making a micaceous product capable of being impregnated preferably in the form of a mica ribbon by combining at least a support and a mica sheet. The invention is characterized in that it consists in: coating the support and the sheet with a solvent-fee resin or a mixture of solvent-free resins using several coating rollers brought to a temperature for producing the coat; combining the support with the mica sheet; subjecting them to a pressure and heat treatment.

Abstract: Unsaturated polyester compositions modified with a polyisocyanate provide low cost thermosetting matrix resins with improve adhesion to carbon fibers. The modified polyester resins are useful in fabricating low cost carbon fiber-reinforced composites.

Abstract: A thermal protection system (TPM) for protecting a surface subject to high thermal load comprising a fiber substrate where the substrate is composed of woven or non-woven layers of fibers laminated together, or the substrate is formed by a process of three-dimensional weaving, wherein the fiber substrate has a variable density of fibers, with said density of fibers increasing across the thickness of the TPM, and further wherein the substrate is needled and coupled to an insulation backing.

Abstract: The invention relates to a coated fiber mat of improved tear strength upon dividing pieces of the coated mat and the coating which comprises a cured, non-woven, fiber glass mat containing a polysiloxane wherein the fibers are fixedly distributed in a formaldehyde type binder containing a binder modifier which is a crosslinked styrene/acrylic polymer, and to a process for the preparation of the mat.

Abstract: A thermal management system utilizing a composite thermal radiation barrier comprising alternating layers of a carbon cloth insulating layer and a silica-based organic cloth to reduce the temperatures experienced by the insulating layer.

Abstract: A rocket motor assembly is insulated or thermally protected with a rocket motor ablative material formed from a prepreg. The prepreg contains at least an impregnating resin matrix and, as a precursor prior to carbonization, either carded and yarn-spun solvent-spun staple cellulosic fibers, solvent-spun cellulosic filaments, or a combination thereof. When patterned and carbonized, the rocket motor ablative material can be lined or otherwise placed into a rocket motor assembly, such as between the solid propellant and case, in the bulk area of the exit nozzle liner, or at susceptible portions of a re-entry vehicle, such as the nose cone.

Abstract: Textile elements made of fibres which contain from 40% to 99.9% silicon dioxide and are coated with a silicone-containing emulsion are disclosed. The emulsion includes an anionically stabilized hydroxylated polydiorganosiloxane contains two hydroxyl groups which are linked with silicone by molecule and colloidal silica. The textile elements demonstrate considerable wear resistance. Methods of preparing the same are also disclosed.

Abstract: An insulation blanket is disclosed that contains fire-blocking materials for preventing rapid penetration of fire into an aircraft fuselage in case of a fire outside the aircraft. The insulation blanket contains at least one layer of fiberglass or other thermal-acoustic insulation material without fire-blocking properties, and one or more layers of fire-blocking material. The fire blocking material is wider than the thermal-acoustic insulation so that it may be folded against and attached to adjacent structural frame members of the fuselage. In the alternative, a thermal-acoustic insulation material is used that has fire-blocking properties instead of the separate layers of fire-blocking and thermal-acoustic insulation materials. A method for installing insulation blankets according to the present invention is disclosed, whereby a fire-blocking insulation portion of the blanket is folded against and attached to frame members of the aircraft using attachment posts or spring clips.

Abstract: A laminated composite mat comprising first and second layers, the first layer comprising an intumescent material and the second layer comprising a plurality of inorganic fibers and a binder which serves to bind the fibers together and to bond the second layer to the first layer. Also described is a process for preparing the composite mat.