Abstract: A process is provided for forming a pre-consolidated fiber preform for use in a molding process. The process includes layering a plurality of preform sheets on a pre-consolidation mold. Heating the plurality of preform sheets to a first temperature. Applying a first pressure to the plurality of preform sheets using the pre-consolidated mold. Maintaining the first temperature and the first pressure and heating for a first duration of time. A second pressure and a second temperature are then applied to the plurality of preform sheets for a second duration of time.

Abstract: A two dimensional unitary preform sheet including a substrate and a fiber bundle arranged on the substrate and attached to the substrate by a plurality of stitches of a thread, which may be a thermoplastic thread. The two dimensional unitary preform sheet is configurable into a three dimensional preform. According to embodiments, the fiber bundle includes carbon fibers, glass fibers, aramid fibers, or a combination thereof. According to embodiments, the two dimensional unitary preform sheet is cut in a pattern that is foldable into the three dimensional preform. A method for making a three dimensional preform is also provided, which includes forming a two dimensional unitary preform sheet and placing the two dimensional unitary preform in a press to bend the two dimensional unitary preform into the shape of the three dimensional preform.

Abstract: A fiber preform for use in a composite material molding process is provided that includes a fiber bundle containing reinforcing fibers. The fiber bundle arranged in parallel switchbacks forming a first layer of the fiber preform. The parallel switchbacks define a principal orientation. A roving is provided that contains reinforcing fibers in a coating. The roving forms stitches on the fiber bundle in a direction substantially perpendicular to the switchbacks so the stitches join the fiber bundle to itself. A method of forming such a fiber preform includes the fiber bundle in the parallel switchbacks being arranged to form the first layer of the fiber preform. The roving forms stitches on the fiber bundle in a direction perpendicular to the switchbacks to join the fiber bundle to itself.

Abstract: A form for a vehicle component includes a commingled fiber bundle composed of thermoplastic fibers and a reinforcement fiber. The reinforcement fiber being glass fibers, aramid fibers, carbon fibers, or a combination thereof. The commingled fiber bundle is laid out in a two-dimensional base layer that defines a shape of the form. An optical fiber is stitched to the commingled fiber bundle. A method of forming a unitary reinforced composite component having a sensor system includes the form being placed onto a mold platen. The preform is heated to promote fusion of the thermoplastic fibers therein. The preform is cooled until solidified with contours of the component. The vehicle component is then removed from the mold platen.

Abstract: A form for a thin reinforced composite material includes a plurality of separate linear fiber strips, each having a rectangular cross section composed of reinforcement fibers. The linear fiber strips laid out in a two-dimensional base layer defining a shape of the form. A first successive layer formed with the plurality of separate linear fiber strips contacting the base layer, the linear fiber strips laid out in the first successive layer interspersed from the separate linear fiber strips in the two-dimensional base layer. A method of forming the form includes arranging the plurality of separate linear fiber strips on a substrate and tacking the plurality of separate linear fiber strips to the substrate with a plurality of stitches. A method of forming a unitary reinforced composite component from the form is further provided. The resulting component having high strength and light weight and being efficient to manufacture.

Abstract: A process is provided for forming a pre-consolidated fiber preform for use in a molding process. The process includes layering a plurality of preform sheets on a pre-consolidation mold. Heating the plurality of preform sheets to a first temperature. Applying a first pressure to the plurality of preform sheets using the pre-consolidated mold. Maintaining the first temperature and the first pressure and heating for a first duration of time. A second pressure and a second temperature are then applied to the plurality of preform sheets for a second duration of time.

Abstract: A needle for use in creating fabric from yam having an elongate, substantially parallel-sided shaft and a tip, the tip having a transition part whose diameter and cross-section substantially matches shaft's diameter and cross section, and a tapered part which tapers from the diameter of the transition part to a point, the Up and shaft being releasably engageable with each other.

Abstract: An article for removing static electricity includes a clean room garment to be worn by a person, the garment including a grid of electrical thread throughout for removing and collecting static electricity from the person; a metal snap at a front waist section of the garment; and an electrical coupling thread in electrical contact from cuff to cuff and electrically connected to the snap for collecting static electricity from the grid and for supplying the collected static electricity to the snap for electrical discharge thereat.

Abstract: A traveller for use in a textile spinning and twisting machine, includes a substantially C-shaped member adapted to engage and travel about a ring of the machine, the member having an outer surface and an inner surface constituting a yarn guide path on which yarn travels, the yarn guide path on the inner surface being free of any mold parting line, the traveller being formed in a mold and the yarn guide path on the inner surface being formed by a groove in an ejector pin of the mold.

Abstract: A conductive yarn includes a continuous non-conductive carrier thread having a relatively low modulus of elasticity; a continuous metal thread; and the carrier thread being wrapped around the metal thread. A process for making such conductive yarn includes the steps of pulling the continuous metal thread off a first package; pulling the continuous carrier thread off a second package; applying a relatively high tension to the carrier thread with respect to the tension on the metal thread as both threads are being pulled off their respective packages; and wrapping the tensioned carrier thread around the pulled metal thread. Apparatus for performing the method is also provided.

Abstract: A conductive yarn includes a continuous non-conductive carrier thread having a relatively low modulus of elasticity; a continuous metal thread; and the carrier thread being wrapped around the metal thread. A process for making such conductive yarn includes the steps of pulling the continuous metal thread off a first package; pulling the continuous carrier thread off a second package; applying a relatively high tension to the carrier thread with respect to the tension on the metal thread as both threads are being pulled off their respective packages; and wrapping the tensioned carrier thread around the pulled metal thread. Apparatus for performing the method is also provided.