Abstract: A mould tool (10) for moulding mouldable material, the mould tool comprises a tool body (12) having a plurality of tool body sections (14), at least two of which comprise an inner polymer foam core (16) within an outer skin (18) of resinous material and are stacked one above the other, the tool (10) further comprises a mould skin (20) extending over the body (12) to provide a mould surface (22) on which mouldable material can be moulded. A method of manufacturing such a mould tool and a tool body are also provided.

Abstract: A curable resin composition containing: (a) at least one resin; and (b) curative selected from the group consisting of (i) a mixture of at least one low temperature curative and at least one high temperature curative or (ii) a curative that has a low temperature curative part and a high temperature curative part wherein the amount of the low temperature curative is sufficient to cause enough resin-curative addition reaction to effect B-staging in the full resin-curative formulation, the amount of the high temperature curative is sufficient to cause the resin to cure catalytically but insufficient to cause resin-curative addition reaction in the final cure, and the ratio of the resin (a) to the curative (b) is greater than or equal to about 5. The present composition may be used to make prepregs for automotive or aerospace application.

Abstract: Disclosed herein is an epoxy resin compositions comprising an epoxy component and a curing agent component, wherein the curing agent component is at least an aminoalkylimidazole curing agent, and wherein the epoxy component and the curing agent component react together at a temperature of about 100° C. to about 130° C. to form a substantially cured reaction product in about 10 minutes or less. Further disclosed are composite products formed from such epoxy resin compositions.

Abstract: A method of moulding a composite structure using a tool having a core support section and a plurality of tool sections surrounding the core support section to define a tool surface on which a composite material can be placed, the core support section being selectively retractable from the tool sections. The composite material is laid on the tool surface and enclosed by a flexible, substantially non-permeable membrane. The enclosed composite material is then cured. The flexible, substantially non-permeable membrane is removed after curing. The core support section is retracted from the tool sections, allowing the tool sections to be collapsed inwardly, thereby releasing the cured composite material from the tool.

Abstract: Curative fibre components comprise one or more fibres for filaments of curative suitable to cure curable resins such as thermoset resin. In curative fibre components comprising a plurality of fibres of curative, the fibres can be commingled, such as twisting, to form a thread or yarn. Curative fibre components can be used to form a material in the form of a sheet, fabric, layer, textile or mat of woven or non-woven curative fibres. Curative fibre components can be used to produce composite materials such as fibre reinforced resinous composite materials. The curative fibre components can be commingled, including interwoven, stitched and layered with other fibres or fibrous materials, such as fibrous reinforcement, fibrous curable resin, fibrous thermoplastic, other non-reinforcing fibres to form composite materials, prepregs, preforms and articles.

Abstract: A tool for use in forming molded articles, comprising a tool body 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 is profiled to define the mold surface(s) of the tool. The outer surface of the tool can be sealed with epoxy sealant to provide the mold surface(s) of the tool. An elastomeric layer can be applied to the surface(s) of the tool body and a resinous material, such as a fiber reinforced material, applied to the elastomeric layer, wherein the elastomeric layer inhibits the movement of resin from the resinous layer into the porous ceramic body, and the resinous layer defines the mold surface.

Abstract: A method of moulding a composite structure using a tool having a core support section and a plurality of tool sections surrounding the core support section to define a tool surface on which a composite material can be placed, the core support section being selectively retractable from the tool sections. The composite material is laid on the tool surface and enclosed by a flexible, substantially non-permeable membrane. The enclosed composite material is then cured. The flexible, substantially non-permeable membrane is removed after curing. The core support section is retracted from the tool sections, allowing the tool sections to be collapsed inwardly, thereby releasing the cured composite material from the tool.

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 molded 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: Disclosed herein is an epoxy resin compositions comprising an epoxy component and a curing agent component, wherein the curing agent component is at least an aminoalkylimidazole curing agent, and wherein the epoxy component and the curing agent component react together at a temperature of about 100° C. to about 130° C. to form a substantially cured reaction product in about 10 minutes or less. Further disclosed are composite products formed from such epoxy resin compositions.