Abstract: The present invention relates to thermoset resin fibre components, composite materials including thermoset resin fibre components, composite articles manufactured using such composite materials and methodologies for manufacturing same. The thermoset resin fibre components may include a single fibre of thermoset resin or a plurality of fibres commingled together. The properties and characteristics of the thermoset resin used are chosen according to the material to be produced therefrom. The thermoset fibre components may be woven into reinforcement fibres to form prepregs. Thermoplastic fibres may be commingled and co-woven with the thermoset fibre components.

Abstract: A tool comprising a support section, a plurality of tool sections beatable around the core section to define one or more tool surfaces on which structure material is beatable to be moulded to form a composite structure, the support section and enclosure means being sealingly engagable to enclose the tool sections and structure material therebetween, thus allowing air to be withdrawn from between the enclosure means and the support section as part of the cure process of the structure material. Sealing the enclosure means directly against the support section obviates the need for the tool sections to be sealingly interconnected.

Abstract: The present invention relates to thermoset resin fiber components, composite materials including thermoset resin fiber components, composite articles manufactured using such composite materials and methodologies for manufacturing same. The thermoset resin fiber components may include a single fiber of thermoset resin or a plurality of fibers commingled together. The properties and characteristics of the thermoset resin used are chosen according to the material to be produced therefrom. The thermoset fiber components may be woven into reinforcement fibers to form prepregs. Thermoplastic fibers may be commingled and co-woven with the thermoset fiber components.

Abstract: A tool (10) for use in forming moulded articles, comprising a tool body (12) formed of a ceramic material, preferably porous with a porosity of between 40% and 60% and in the form of a foam. The tool body (12) is profiled to define the mould surface(s) of the tool (10). The outer surface (11) of the tool (10) can be sealed with epoxy sealant to provide the mould surface(s) of the tool. An elastomeric layer (16) can be applied to the surface(s) of the tool body (12) and a resinous material (14), such as a fibre reinforced material, applied to the elastomeric layer (16), wherein the elastomeric layer (16) inhibits the movement of resin from the resinous layer (14) into the porous ceramic body, and the resinous layer (14) defines the mould surface.

Abstract: The invention provides moulding materials methodology for manufacturing such moulding materials, articles moulded from such materials, kits and methodology for moulding articles using said materials, the moulding materials comprising a fibrous material comprising continuous reinforcement fibres at least some of which are cut at least one point along their length. Continuous reinforcement fibres are generally unidirectional fibres, woven, knitted, braided or stitched fibrous materials.

Abstract: A curable resinous material, and a method of manufacturing same, the curable resinous material comprising a resinous matrix material (R) with thermoplastic material (TP) distributed therein, some of said thermoplastic material (TP) being substantially fully dissolved in the matrix resin material (R) with other of the thermoplastic materials (TP) being only partially dissolved within the matrix material (R) when the resinous material is cured. The invention also provides a curable resinous material, and a method of manufacturing same, comprising a resinous matrix material (R) and a thermoplastic material (TP) distributed within the resinous matrix material (R) so that at least some of said thermoplastic material (TP) remains partially undissolved in the resinous matrix material (R) when cured.

Abstract: The present invention relates to thermoset resin fibre components, composite materials comprising thermoset resin fibre components, composite articles manufactured using such composite materials and methodologies for manufacturing same. The thermoset resin fibre components may comprise a single fibre of thermoset resin or a plurality of fibres commingled together. There properties and characteristics of the thermoset resin used are chosen according to the material to be produced therefrom. The thermoset fibre components may be woven into reinforcement fibres to form prepregs. Thermoplastic fibres may be commingled and co-woven with the thermoset fibre components.

Abstract: A method of manufacturing a composite and of securing a metallic coating to a resin-based composite material, comprising the provision of a keying structure on a metallic electroplated preform and bringing the keying structure and the composite material together under conditions to cause the composite material and the keying structure to interlock. The invention also provides a composite comprising a resin-based composite material with a metallic coating on a surface, or part surface thereof, the metallic coating comprising an outer electroplated preform, and an inner keying structure which is located generally between said electroplated preform and the composite material to provide attachment of the electroplated preform on the composite material.

Abstract: A tool on which material (M) can be moulded to form a moulded article, the tool comprising a surface, which may be provided on a surface layer, defining one or more pathways for the removal of gaseous material from beneath the material (M) being moulded on the tool.

Abstract: A tool for use in forming moulded articles, the tool comprising a tool body formed of a foamed material, a resinous material on the tool body and elastomeric material between said tool body and resinous material to inhibit the movement of resin from the resinous material into the tool body. The invention also provides a method of manufacturing a tool, a method of moulding articles using such a tool, and elastomeric material for use in forming a tool. One particular application of the tools of the present invention is in the formation or manufacture of moulded articles using curable, resinous composite materials.