Abstract: A tool for manufacturing a preform assembly; comprising an inverted “Upper Skin” Preform Mold (101) having mold surface (75) turned up-side down so that gravity will help hold pre-preg layers on the mold surface (75) during performing; a “Web” Preform Mold (105) with flanges (76); and a “Lower Skin” Preform Mold (110), having a mold surface (78) with leading edge overlap extension (79) and trailing edge overlap extension (80).

Abstract: A method and apparatus for coating reactive polymer pre-impregnated reinforcement material (prepregs). The method comprising continuously applying particles of a reactive thermoplastic resin to a first surface of a porous substrate, followed by continuously coating the reactive polymer prepreg. An apparatus for coating reactive polymer pre-impregnated reinforcement material (prepregs), comprising: feeder roll(s) of reinforcement material, receiver roll(s) of drapable polymer pre-impregnated reinforcement material, a conveyor belt having the reinforcement material from the feeder roll thereon, and deposition units for depositing the coating.

Abstract: An apparatus and method for forming a shape of a composite assembly, comprising: a mold having a first surface and a vacuum bag thereon, wherein the vacuum bag comprises a plurality of vacuum bag sheet(s), and a composite assembly therein, wherein the composite assembly comprises a plurality of bondable layers, wherein at least one of the plurality of sheet(s) of the vacuum bag is between the plurality of bondable layers and the first surface of the mold, and wherein the plurality of bondable layers are able to retain a shape which is the negative image of the mold when the pressure of the inside of the vacuum bag is reduced, even if the bag and plurality of bondable layers of the composite assembly are removed from the mold.

Abstract: A method and apparatus for making a reactive polymer pre-impregnated reinforcement material, comprising applying a substantially non-volatile composition of substantially solid particles of a reactive thermoset resin to a porous substrate at ambient temperature, initially by melting a first portion of the particles of the reactive thermoset resin. The first portion of the particles of the reactive thermoset resin flows into interstices of at least one layer of the porous substrate and a remaining portion of the particles of the substantially non-volatile composition remains solid.

Abstract: A method and apparatus for making a reactive polymer pre-impregnated reinforcement material, comprising applying particles of a reactive thermoplastic resin to a first surface of a porous substrate at ambient temperature. The porous substrate may be impregnated by melting a first portion of the particles of the reactive thermoplastic resin. The first portion of the particles of the reactive thermoplastic resin flows into interstices of the first surface of the porous substrate and a remaining portion of the particles of the curable thermoplastic resin remains solid. An apparatus for forming a drapable polymer pre-impregnated reinforcement material, comprising: a feeder roll of reinforcement material, a receiver roll of drapable polymer pre-impregnated reinforcement material and a conveyor belt having the reinforcement material from the feeder roll thereon, and a particle deposition hopper adapted to deposit between 240 g/m2 and about 470 g/m2 of reactive thermoplastic particles.