Abstract: A product sheet of composite material can be made by disposing composite materials of composite material in adjacent (side-by-side) relation with each other. The composite materials comprise fibers in a thermoplastic matrix material. The adjacent composite materials are bonded together to provide a product sheet of composite material. Preferably, a cross ply of composite material is disposed on the composite materials. The cross ply may be a unidirectional sheet and the fibers in the cross ply may be disposed in transverse relation to the fibers in the composite materials.

Abstract: A moldable composite material contains flakes of composite material, i.e., flakes of polymeric matrix materials having fibers embedded therein. An improved substrate is provided by providing a substrate and applying a coating onto the substrate, the coating containing the flakes of composite material. A first construction member can be secured to a second construction member by applying the coating onto an attachment region of the first construction member, and applying a fastener onto the first construction member in the coated attachment region to secure the first construction member to the second construction member.

Abstract: A product sheet of composite material can be made by disposing composite materials of composite material in adjacent (side-by-side) relation with each other. The composite materials comprise fibers in a thermoplastic matrix material. The adjacent composite materials are bonded together to provide a product sheet of composite material. Preferably, a cross ply of composite material is disposed on the composite materials. The cross ply may be a unidirectional sheet and the fibers in the cross ply may be disposed in transverse relation to the fibers in the composite materials.

Abstract: A moldable composite material contains flakes of composite material, i.e., flakes of polymeric matrix materials having fibers embedded therein. An improved substrate is provided by providing a substrate and applying a coating onto the substrate, the coating containing the flakes of composite material. A first construction member can be secured to a second construction member by applying the coating onto an attachment region of the first construction member, and applying a fastener onto the first construction member in the coated attachment region to secure the first construction member to the second construction member.

Abstract: A suspension sub-assembly includes a fiber reinforced polymeric (FRP) thermoplastic composite upper control arm/spring assembly having a control arm portion and a spring member portion. The suspension sub-assembly can tune roll stiffness of a vehicle during cornering. The FRP thermoplastic composite upper control arm/spring assembly comprises a thermoplastic matrix material reinforced with fibers embedded and aligned in the matrix of the assembly.

Abstract: Disclosed is a composite structure including a laminate integrally bonded to a substrate. The laminate includes a composite ply having a plurality of fibers in a thermoplastic matrix.

Abstract: A moldable composite material contains flakes of composite material, i.e., flakes of polymeric matrix materials having fibers embedded therein. An improved substrate is provided by providing a substrate and applying a coating onto the substrate, the coating containing the flakes of composite material. A first construction member can be secured to a second construction member by applying the coating onto an attachment region of the first construction member, and applying a fastener onto the first construction member in the coated attachment region to secure the first construction member to the second construction member.

Abstract: A fire resistant composite laminate includes a thermoplastic matrix material reinforced with fibers embedded in the matrix of the composite laminate, wherein the thermoplastic matrix material of the fire resistant composite laminate includes polyvinylidene fluoride (PVDF).

Abstract: A product sheet of composite material can be made by disposing composite materials of composite material in adjacent (side-by-side) relation with each other. The composite materials comprise fibers in a thermoplastic matrix material. The adjacent composite materials are bonded together to provide a product sheet of composite material. Preferably, a cross ply of composite material is disposed on the composite materials. The cross ply may be a unidirectional sheet and the fibers in the cross ply may be disposed in transverse relation to the fibers in the composite materials.

Abstract: A composite laminate is made by providing at least a first composite ply and a second composite ply, each having longitudinally oriented fibers in a thermoplastic matrix. The second composite ply is disposed on, and in transverse relation to, the first composite ply. Preferably, the second ply is disposed at 90° relative to the first ply. An article can be manufactured by providing a core material and applying a reinforcing material to a portion of the core material. The reinforcing material is a reinforcing composite ply or a composite laminate as described herein. Optionally, the core material is a prepreg that may be a composite laminate.

Abstract: A composite leaf spring comprising a thermoset matrix material reinforced with fibers embedded in the matrix of the composite leaf spring.

Abstract: A composite leaf spring comprising a thermoplastic matrix material reinforced with fibers embedded and aligned in the matrix of the composite leaf spring.

Abstract: A moldable composite material contains flakes of composite material, i.e., flakes of polymeric matrix materials having fibers embedded therein. An improved substrate is provided by providing a substrate and applying a coating onto the substrate, the coating containing the flakes of composite material. A first construction member can be secured to a second construction member by applying the coating onto an attachment region of the first construction member, and applying a fastener onto the first construction member in the coated attachment region to secure the first construction member to the second construction member.

Abstract: A composite laminate is made by providing at least a first composite ply and a second composite ply, each having longitudinally oriented fibers in a thermoplastic matrix. The second composite ply is disposed on, and in transverse relation to, the first composite ply. Preferably, the second ply is disposed at 90° relative to the first ply. An article can be manufactured by providing a core material and applying a reinforcing material to a portion of the core material. The reinforcing material is a reinforcing composite ply or a composite laminate as described herein. Optionally, the core material is a prepreg that may be a composite laminate.

Abstract: A composite structure (10) includes a first outer skin (12); a second outer skin (14); and a core (16) sandwiched between the first outer skin (12) and the second outer skin (14). The core (16) includes a plurality of spaced apart ridges (18) between the first outer skin (12) and the second outer skin (14), each of the spaced apart ridges (18) extending from one end (20) of the composite structure (10) to an opposite end (22); and a plurality of connecting elements (24) between the first outer skin (12) and the second outer skin (14) configured to intersect with the ridges (18) to form open channels (26) within the core (16).

Abstract: A composite laminate comprises a plurality of composite plies including at least a first composite ply and a second composite ply. The first composite ply and the second composite ply each comprises a plurality of fibers in a thermoplastic matrix comprising polyethylene. The plurality of composite plies are bonded together to form the composite laminate.

Abstract: A blade comprises a lightweight core, a composite material disposed on the core, and a skin located on the composite material. The composite material comprises fibers incorporated into a thermoplastic resin matrix in the form of a prepreg sheet or wet layup. The rotor blade may also comprise a front edge member attached along at least a portion of a leading edge of the core, a rear edge member attached along at least a portion of a trailing edge of the core, and a skin located over the core, the front edge member, and the rear edge member. The rotor blade may also comprise a spar extending through the core along a longitudinal axis of the rotor blade, and a skin located over the core and the spar. The edge members and the spars may be fabricated from thermoplastic material.

Abstract: A blade comprises a lightweight core, a composite material disposed on the core, and a skin located on the composite material. The composite material comprises fibers incorporated into a thermoplastic resin matrix in the form of a prepreg sheet or wet layup. The rotor blade may also comprise a front edge member attached along at least a portion of a leading edge of the core, a rear edge member attached along at least a portion of a trailing edge of the core, and a skin located over the core, the front edge member, and the rear edge member. The rotor blade may also comprise a spar extending through the core along a longitudinal axis of the rotor blade, and a skin located over the core and the spar. The edge members and the spars may be fabricated from thermoplastic material.