Abstract: A composition for the promotion of adhesion between a rubber formulation and a textile substrate is provided. The inventive composition comprises either a mixture of specific amine functional silanes and organo-functional silanes having reactive groups or groups with an affinity for rubber. The inventive method entails the use of the inventive composition or a silane compound having both an amine moiety and a reactive group having an affinity for rubber formulations, particularly an unsaturated carbon-carbon bond. The composition may be utilized to adhere any standard reinforcement-type textile, such as polyester or polyamide, to a standard rubber composition, such as SBR, NBR, or EPDM. A method for adhering textiles to rubber formulations is also provided involving a pre-dip, -spray, -coat, and the like, of the inventive composition on a reinforcement-type textile surface followed by the contacting of the rubber formulation.

Abstract: A core crush resistant prepreg for use in making a fiber reinforced composite panel structure is provided. The prepreg comprises a woven fabric consisting essentially of carbon fiber tow strands impregnated with a hardenable polymeric resin composition. Typically the fabric has an areal weight of from about 180 to about 205 grams per square meter. The prepreg has an average fiber tow aspect ratio of less than about 15.4, a prepreg thickness of at least about 0.245 mm, and a prepreg openness of at least about 1.2 percent but less than about 6.0 percent. Preferably, the resin composition is predominantly viscous in nature and has a tan &dgr; value of between 0.9 and 2.0 at an elevated temperature between 70° C. and 140° C., and an average epoxy functionality of greater than 2.0. A method for evaluating core crush resistance properties of a prepreg is also provided.

Abstract: Carbon fiber including graphitized fiber is processed electrochemically in an acidic solution for a time sufficient to run a layer reaction such that the reaction extends to the inside of the fiber and thereafter, as required, heat-treated accurately at 100° C. or more to expand layer spacing to form multifibrous carbon fiber, with which hydrogen is brought into contact, adsorbing hydrogen in the inside of the multifibrous carbon fiber.

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: Composite coating (10) improves the resistance to blast or seismic forces of a structure (100), such as wall (101). Coating (10) includes a first layer (20) of elastomeric polyurethane in contact with and adhering to wall (101), a second layer (30) of elastomeric polyurethane in contact with and adhering to first layer (20), and a layer of textile (40) embedded between first layer (20) and second layer (30).

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: The invention relates to an external reinforcement for beams, columns, plates and the like, substantially consisting in the combination of fibers and a resin and whereby the majority of the fibers is situated in the longitudinal direction of the reinforcement, characterized in that at least well-defined portions of the external reinforcement are provided with an additional reinforcement formed by fibers which are arranged according to at least one direction differing from the longitudinal direction of the reinforcement.

Abstract: An improved decorative laminate and method for making the improved decorative laminate having a protective layer, an embossable layer, and a substrate layer; the protective layer being a transparent tough resin material such as polyvinylidene fluoride (PVDF) with a design printed thereon, the embossable layer being a pigmented embossable resin, and the substrate layer being a fiber material. As a result of the pigmentation of the embossable layer, preferably with the predominant color of the design, scratches through the protective layer are not particularly noticeable since the pigmented embossable layer will be exposed which matches the predominant color of the design.

Abstract: A high-purity carbon fiber reinforced carbon composite formed by a process which entails graphitizing a molded member packed with carbon fibers, which fibers are subjected to a purification process under halogen gas prior to being graphitized and prior to being packed with a matrix of carbon material, and the matrix of carbon material, the carbon fiber reinforced carbon composite having an impurities content of not more than 30 ppm in ash content and satisfies either or both of the following conditions for impurities: (1) V is not more than 0.12 ppm by ICP-OES; and (2) Fe is not more than 0.10 ppm by ICP-OES.

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: A core crush resistant prepreg for use in making a fiber reinforced composite panel structure is provided. The prepreg comprises a woven fabric consisting essentially of carbon fiber tow strands impregnated with a hardenable polymeric resin composition. Typically the fabric has an areal weight of from about 180 to about 205 grams per square meter. The prepreg has an average fiber tow aspect ratio of less than about 15.4, a prepreg thickness of at least about 0.245 mm, and a prepreg openness of at least about 1.2 percent but less than about 6.0 percent. Preferably, the resin composition is predominantly viscous in nature and has a tan &dgr; value of between 0.9 and 2.0 at an elevated temperature between 70° C. and 140° C., and an average epoxy functionality of greater than 2.0. A method for evaluating core crush resistance properties of a prepreg is also provided.

Abstract: A liner for a high pressure gas container includes a resin composition containing a polyphenylene sulfide resin and an olefin based resin. The resin composition has a methane gas permeability coefficient of 1.7×10−16 mol·m/m2·s·Pa or smaller at 40° C., and tensile elongation of 50% or greater after fracture at 23° C. A high pressure gas container having such a liner is also provided.

Abstract: Methods for producing by electrochemical reduction a carbon-containing material with its surface modified by organic groups, in particular functionalized organic groups. Certain embodiments of the methods include contacting the carbon-containing material with an organic diazonium salt in solvent, optionally in the presence of an electrolyte and negatively polarizing the carbon-containing material relative to an anode also in contact with an electrolytic solution separate from said diazonium salt solution, wherein the electrochemical reduction is carried out on an organic diazonium salt in protic solvent in an acid medium. Carbon-containing materials with a surface modified by organic groups and the use of these modified materials, for example for producing composite materials or for fixing molecules of biological interest, are taught.

Abstract: The high purity C/C composite formed by graphitizing a molded member packed with carbon fibers and carbon material of a matrix. The carbon fibers are high purified under halogen gas atmosphere. The purified carbon fibers are molded into the desired shape on a tool or in die with infiltrating the matrix. The molded member packed with carbon fibers and carbon material of the matrix are either independently or simultaneously graphitized and then high-purification under halogen gas atmosphere. According to the present process, the metal impurities can be very low contents.

Abstract: An aqueous binder composition containing a urea-formaldehyde resin modified with an additive comprising (1) styrene acrylic acid or styrene acrylate, (2) an adduct of styrene, maleic anhydride, and an acrylic acid or acrylate or (3) a physical mixture of a styrene acrylic acid or styrene-acrylate copolymer and a styrene-maleic anhydride copolymer. The resulting binder is used in the preparation of fiber mats.

Abstract: Lightning protection utilizing lightweight electrically conductive coatings with a conductance of approximately 220 to 350 mhos per square co-cured or secondarily bonded to the outer surface of thin skin composite structure. Selection of either 2 to 3 ounces per square yard or aluminum mesh of 1 to 1.5 ounces per square yard, depending on corrosion compatibility, satisfy the conductance requirement and has shown superior lightning protection over heavier weight conductive coatings.

Abstract: A semiconducting floor covering which consists of a layer (2) of conductive material parallel to the surface of the covering and at least one layer (1, 3) of polyvinyl chloride based material adhered to the layer of conductive material. As plasticizer for the polyvinyl chloride in the floor covering, 2-ethyl hexyl diphenyl phosphate and aliphatic ester compound has been used or these two combined so that per 100 parts of polyvinyl chloride it contains 39-80 parts of plasticizer. It further contains 1-250 parts of talc and/or ATH as filler.

Abstract: Since the dense and high purity pyrolytic-carbon-coated layer is formed with a thickness of 10-100 &mgr;m on the surface of the C/C composite, even when metallic impurities of the inside C/C composite are 5-100 ppm in ash content, similar effects to those of a known crucible made of the C/C composite whose inside was subjected to high purification can be produced to achieve full applicability to the structural elements of the CZ apparatus. Also, since the process time required or the C/C composite itself to be subjected to the high purification can be shortened, the effect of reducing the manufacturing costs considerably can be obtained.

Abstract: A joint and method for forming a joint between two spaced apart materials having dissimilar coefficients of thermal expansion wherein the space is filled with a blended composite of twisted fibrils of the two materials, preferably quartz and carbon, and an adhesive, preferably an epoxy based adhesive.

Abstract: Boeing is actively engaged in the production of lightweight composite airframes for both military and commercial applications. The double bag vacuum infusion process of the present invention provides a low cost, method for producing complex composite assemblies without an autoclave. It also enables the production of highly innovative structures. The quality of the composites produced using such an infusion process are comparable to composites made using prepregs, hand layup or fiber placement, and autoclave curing.

Abstract: A core crush resistant prepreg for use in making a fiber reinforced composite panel structure is provided. The prepreg comprises a woven fabric consisting essentially of carbon fiber tow strands impregnated with a hardenable polymeric resin composition. Typically the fabric has an areal weight of from about 180 to about 205 grams per square meter. The prepreg has an average fiber tow aspect ratio of less than about 15.4, a prepreg thickness of at least about 0.245 mm, and a prepreg openness of at least about 1.2 percent but less than about 6.0 percent. Preferably, the resin composition is predominantly viscous in nature and has a tan &dgr; value of between 0.9 and 2.0 at an elevated temperature between 70° C. and 140° C., and an average epoxy functionality of greater than 2.0. A method for evaluating core crush resistance properties of a prepreg is also provided.

Abstract: A novel class of carbon fiber precursor derived carbon foams and a method for their production are described. A new class of C/C composites comprising unidirectional or woven carbon fabrics in a matrix of the novel carbon foams, and the method for their production are also described.

Abstract: Aromatic polyamide fibers which have a crystalline structure having (1) crystal size (A) in a (110) plane of 7.5 nm, (2) crystal size (B) in a (200) plane of 8.2 nm and (3) a product A×B of 61.50 to 630.00, and exhibit a thermal linear expansion coefficient of −1.0×10−6/° C. to −7.5×10−6/° C. and thus a high dimensional stability even upon moisture-absorbing and desorbing, are useful for forming a resin-reinforcing fiber sheet, a pre-preg containing the fiber sheet, and a laminate for, for example, an electric insulating material or electric circuit board, having an excellent cutting, shaving, perforating or laser processability and capable of forming a smooth cut, shaved or perforated face.

Abstract: A high temperature and energy capacity friction material for wet brake and clutch applications comprising a resin impregnated carbon fabric. Preferably, the fabric is a woven cloth and the resin is a thermoset such as phenolic resin. The invention involves the controlled impregnation of the fabric so as to leave the fabric with a high compressive strength, effectively impervious to internal oil flow, but with macroscopic voids between the tows of yarn to afford local reservoirs of oil at the working surface and flow of oil across the working surface.

Abstract: A reinforcing grid which advantageously includes fibers of both a first type and a second type is provided. The first type of fibers have a strength sufficient to reinforce the hardenable structural material, such as concrete, after hardening. The first type of fibers also have a higher resistance to degradation in the hardenable material than the second type of fibers. As such, the first type of fibers will continue to reinforce the hardened material in the event the fibers of the second type become corroded in the hardened material. Consequently, a less expensive type of fiber can be used as the second type of fiber and can corrode in the hardenable material without concern for the strength of the hardened structural product. According to one embodiment, the first type of fibers comprises carbon fibers and the second type of fibers comprises glass fibers.

Abstract: A core crush resistant prepreg for use in making a fiber reinforced composite panel structure is provided. The prepreg comprises a woven fabric consisting essentially of carbon fiber tow strands impregnated with a hardenable polymeric resin composition. Typically the fabric has an areal weight of from about 180 to about 205 grams per square meter. The prepreg has an average fiber tow aspect ratio of less than about 15.4, a prepreg thickness of at least about 0.245 mm, and a prepreg openness of at least about 1.2 percent but less than about 6.0 percent. Preferably, the resin composition is predominantly viscous in nature and has a tan &dgr; value of between 0.9 and 2.0 at an elevated temperature between 70° C. and 140° C., and an average epoxy functionality of greater than 2.0. A method for evaluating core crush resistance properties of a prepreg is also provided.

Abstract: A carbon/carbon composite in which a carbon matrix containing a controlled amount of boron or a boron compound is reinforced with carbon fiber exhibits a low coefficient of friction, i.e., on the order of 0.04 to 0.1 at temperatures up to 600° C., which is one of the lowest frictional coefficients for any type of carbonaceous material, including graphite, glassy carbon, diamond, diamond-like carbon and other forms of carbon material.

Abstract: The present invention relates to a fibrous base material for use in a non-asbestos, non-metallic friction material comprising less fibrillated aramid fibers, carbon particles, cotton fibers, carbon fibers and at least one filler material, and the non-asbestos, non-metallic friction material produced therefrom. In certain embodiments, the fibrous base material is impregnated with a phenolic or phenolic-base resin material, including, for example, a mixture of a phenolic resin and a silicone resin.

Abstract: A carbon fiber woven fabric constituted by carbon fibers having a thermal conductivity of at least 400 W/m.multidot.K in the fiber axial direction, which has a FAW (weight per unit area of fabric) of at lest 400 g/m.sup.2.

Abstract: Lightning protection utilizing lightweight electrically conductive coatings with a conductance of approximately 220 to 350 mhos per square co-cured or secondarily bonded to the outer surface of thin skin composite structure. Selection of either 2 to 3 ounces per square yard or aluminum mesh of 1 to 1.5 ounces per square yard, depending on corrosion compatibility, satisfy the conductance requirement and has shown superior lightning protection over heavier weight conductive coatings.

Abstract: An aqueous binder composition containing a urea-formaldehyde resin modified with a water-soluble styrene-maleic anhydride copolymer is used in the preparation of fiber mats.

Abstract: A chemical process apparatus component comprising a high purity, corrosion resistant composite including a continuous carbon fiber reinforced carbon matrix having a level of total metal impurity below about 10 ppm, preferably below about 5 ppm. Most preferably, the composite has a level of metal impurity below the detection limit of inductively coupled plasma spectroscopy for the metals Ag, Al, Ba, Be, Ca, Cd, Co, Cr, Cu, K, Mg, Mn, Mo, Na, Ni, P, Pb, Sr and Zn.

Abstract: The present invention relates to a printed circuit board and a printed circuit board base material for use in the printed circuit board. The printed circuit board base material of the present invention is produced by impregnating a carbon core material such as carbon cloth with a first resin such as epoxy resin, and the printed circuit board of the present invention is characterized in that resin pores are opened on the printed circuit board base material, second resins such as epoxy resins are filled in the resin pores, circuit layers are formed on the printed circuit board base material, through holes connecting the circuit layer together are provided, and the center line of the resin pore is approximately in line with the center line of the through hole.

Abstract: The present invention relates to a fibrous base material comprising a primary layer of less fibrillated aramid fibers, carbon particles, carbon fibers, phenolic novoloid fibers, and at least one filler material, optionally cotton fibers, and a secondary layer of carbon particles on at least one surface of the fibrous base material for use in a non-asbestos friction material. In certain embodiments, the fibrous base material is impregnated with a phenolic or phenolic-based resin material, including, for example, a mixture of a phenolic resin and a silicone resin to form a friction material having an extended high speed durability life, good "break-in" characteristics, good heat dissipation characteristics, and good noise or squawk resistance.

Abstract: A chemical process apparatus component comprising a high purity, corrosion resistant composite including a continuous carbon fiber reinforced carbon matrix having a level of total metal impurity below about 10 ppm, preferably below about 5 ppm. Most preferably, the composite has a level of metal impurity below the detection limit of inductively coupled plasma spectroscopy for the metals Ag, Al, Ba, Be, Ca, Cd, Co, Cr, Cu, K, Mg, Mn, Mo, Na, Ni, P, Pb, Sr and Zn. A process utilizing at least one of the above components for use in a chemical process apparatus, wherein said component is in contact with at least one of i) a high purity material, such as for processing, and ii) a corrosive process media.

Abstract: There are described a self-adhesive prepreg on the basis of a resin-impregnated fibrous supporting material carrying on at least one surface a layer with an increased ratio of resin to supporting material, and the use thereof for the production of sandwich structures.

Abstract: A composite article comprising of a non-metallic composite core, a fluoroelastomer adhesive layer which has a curing temperature substantially similar to the composite core, and a metallic structure which overlays the fluoroelastomer adhesive layer, wherein the composite article can be formed by co-curing the core and the fluoroelastomer adhesive layer.

Abstract: A flexible mat is provided having a nonwoven fabric having first and second major surfaces; and a coating of metal oxide on only a portion of at least one of the major surfaces.

Abstract: The present invention provides a novel amorphous carbon-coated carbon fabric which comprises a single ply of a woven carbon fabric comprising interwoven strands of yarn. The yarn strands are formed of bundles of individual fibers and have amorphous carbon disposed between the individual fibers.The present invention also relates to a method of forming an amorphous carbon-coated carbon fabric. The method comprises the steps of (1) impregnating a woven carbon fabric with a resin; and (2) heating the resulting resin-impregnated carbon fabric to a temperature which is sufficient to char the resin to form a residue of amorphous carbon, thereby forming an amorphous carbon-coated carbon fabric material.

Abstract: A woven fabric to be used in formation of a composite material includes multifilament warp and weft threads. Each of the warp threads and the weft threads have a total weight less than 80% of the weight of the fabric. The woven warp and weft threads have O twist/m and a torsion no greater than an original torsion of the threads before weaving. Each woven warp and weft thread has a width over the entire length thereof that is greater than or equal to an original width before weaving. The fabric is woven to have a given weight per unit area and a fiber volume ratio that is approximately constant throughout the fabric and that is satisfactory for use of the fabric in a composite material. The warp and weft threads of a yarn count that is greater than a yarn count traditionally used to achieve the fiber volume ratio for the given weight per unit area.

Abstract: Reinforcement of structures in high-moisture environments is achieved by applying reinforcement layers which include a fabric portion and an uncured resin portion where the uncured resin contains a moisture curable silicon-modified polyether resin. The uncured reinforcement layer is cured in place about the structure to form a composite reinforcement shell. The uncured reinforcement layer is formed from either dry-woven fabric or woven fabric which is pre-impregnated with a cured resin and then coated with the moisture-curable silicon-modified polyether resin. The invention finds particular use in reinforcing bridge supports and pilings which are at least partially submerged in water. Containment layers are used to prevent de-lamination during curing of the reinforcement structure. Use of a containment layer not only prevents de-lamination caused by waves or other turbulent water, but also enhances the underwater curing process.

Abstract: The present invention is directed to polymer compositions containing a vinyl polymer component (A), formed by polymerization of .alpha.,.beta.-ethylenically unsaturated monomers, one which contains at least one hydroxyl group and one which contains no hydroxyl groups; a crosslinker component (B); an additive component (C); and a solvent component (D). The composition is useful for backcoating woven substrates and as a binder composition for non-woven substrates.

Abstract: A method for preparing an uncured supported elastomer material includes the steps of: providing a fibrous reinforcement material; providing a layer of uncured elastomer material substantially adjacent to the fibrous reinforcement material; exposing the layer and the fibrous reinforcement to a temperature below a curing temperature and above a flow point of the uncured elastomer material, and a pressure sufficient that the uncured elastomer material flows into the fibrous reinforcement material, so as to provide an uncured supported elastomer material.

Abstract: There is disclosed a prepreg including noncircular cross-section carbon fibers and a matrix resin having a flexural elastic modulus of 2.7 GPa or more and a water absorption of 3.4% or less under hot-wet conditions after curing; and another prepreg including carbon fibers and a matrix resin having an open-hole compression strength under hot-wet conditions and a compression strength after impact under room-temperature conditions of a quasi-isotropic material after curing of each 275 MPa or more. Carbon fiber-reinforced composite materials produced by curing these prepregs are excellent in open-hole compression strength under hot-wet conditions and in compression strength after impact, and can be suitably used especially as an aircraft primary structure material.

Abstract: A ternary composite with thermal stability of up to at least 200.degree. C. Is formed using a thermally stable matrix resin, high tensile fibers, and borosilicate or sodium tetra borate glass particulates. The composite has stability to acids, toxic wastes and may be formed into sheets, shapes, tubes, containers, flooring materials and the like for use in aerospace, defense, automotive, industrial, nuclear containment or simply building material applications.

Abstract: A method of preparing an adhesive composite is provided where a fluoropolymer having nodes and interconnected fibrils with a void volume formed from the node and interconnected fibril structure is at least partially filled with a paste formed from a thermoset or thermoplastic adhesive and a particulate vapor phase formed inorganic filler having uniform surface curvature, sufficient adhesive and filler are present to provide a composite having between about 5 to about 40 volume percent polymeric substrate, 10-95 volume percent adhesive and filler imbibed within the voids of said substrate and 5 to 85 volume percent inorganic filler is contained within the composite. In the composite, the ratio of mean flow pore size to largest particle size is at least above 0.7; or the ratio of mean flow pore size to average particle size is greater than 1.5; or the ratio of minimum pore size to average particle size is at least above 0.8; or the ratio of minimum pore size to largest particle size is at least above 0.4.

Abstract: A Czochralski process furnace component comprises a high purity, semiconductor standard composite including a carbon fiber reinforced carbon matrix having a total level of metal impurity below about 10 ppm, preferably below about 5 ppm, and most preferably having a level of metal impurity below the detection limit of inductively coupled plasma spectroscopy for the metals Ag, Al, Ba, Be, Ca, Cd, Co, Cr, Cu, K, Mg, Mn, Mo, Na, Ni, P, Pb, Sr and Zn. A crucible susceptor for a crystal growing process for pulling a crystal ingot from a crystal material melt in a crucible comprises a high purity composite comprising a two dimensional, continuously woven carbon fiber fabric reinforced carbon matrix; the high purity composite having a total level of metal impurity less than about 10 parts per million; the crucible susceptor being a one piece, ply lay-up structure of said high purity composite, having a side ring and a base, said side ring and said base having substantially the same thickness.

Abstract: The present invention relates to thermoplastically formable composite materials of reinforcing fibers in a polyamide 12 matrix, characterized in that the polyamide 12 matrix consists of anionically polymerized laurin-lactam maximally containing 15 weight-% of co-monomers and selectively additives which are determined on the basis of production, processing and use. The invention furthermore relates to a process for producing these composite materials, in accordance with which an activated anionic lactam 12 melt is prepared, which penetrates the fiber arrangement in the liquid state, so that it forms the matrix for a shaped body, the activated melt is final-polymerized under the effects of temperature and pressure in a mold or a tool in such a way that the shape is achieved, and the pre-formed part is subjected to an after-shaping step under the effects of pressure and temperature, if desired.

Abstract: A fiber reinforced composite structure and method for fabricating the composite, are described wherein four sets of mechanically flexible fibers are interwoven in a three-dimensional woven structure wherein each fiber is woven through the structure generally along one of the four directions defined generally parallel to a body diagonal of a cube, and wherein the woven structure is impregnated with polymeric, metallic or ceramic matrix material to form a composite material which is braced against deformation by shear applied in any orientation.