Abstract: A form for a vehicle component is provided that includes a commingled fiber bundle composed of a reinforcement fiber. The commingled fiber bundle is laid out in a two-dimensional base layer that defines a shape of the form. A conductive fiber or wire laid in a pattern on the two-dimensional base layer to provide electrical continuity across the form. At least one conductive contact or pad area is built up with overlying layers of the conductive fiber or wire on said two-dimensional base layer. A successive layer is added to embed the conductive fiber or wire and at least one conductive contact or pad area. A conductive fastener is inserted into through hole apertures therein. The conductive fastener is in electrical communication with the corresponding conductive contact or pad area. A method of forming a unitary reinforced composite component is also provided.

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 net-shape ballistic panel is formed by a process of arranging a fiber bundle on a substrate to form a layer, the layer following a shape of the ballistic panel, securing the fiber bundle to the substrate with a plurality of stitches to form a preform layer, arranging additional layers of fiber bundles on the preform layer, each layer of the additional layers following the shape of the ballistic panel, and each fiber bundle being secured with a plurality of stitches to each layer of the additional layers to form a plurality of preform layers. A resin is then impregnated into the preform layers and subsequently cured using a process such as compression molding. The resulting ballistic panel is relatively thin while exhibiting an excellent ballistic rating (e.g., V50).

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 coated tow includes a fiber bundle composed of continuous reinforcement fibers that form a flat substrate in a ribbon shape and a thermoplastic-based overcoating applied to the flat substrate to form a uni-directional tape. An extruded tape includes a plurality of cords of twisted fiber yarns each composed of continuous reinforcement fibers, a thermoplastic overcoating applied to each of the cords, and a high density polyethylene (HDPE) that encases the plurality of cords to form a uni-directional tape. The reinforcement fibers have continuous filaments aligned lengthwise along a length each of the cords. A process of producing the coated tow or extruded tape includes feeding one or more spools of continuous fiber tow under tension control, sinking the continuous fiber tow in a chemical bath, passing the wetted continuous fiber tow through one or more squeezing rollers, and passing the continuous fiber tow through an oven.

Abstract: A fiber preform for use in a resin transfer molding or liquid composite molding process and process of making the same are provided. The preform includes a substrate, a fiber bundle arranged on the substrate in a predetermined pattern and attached to the substrate by a plurality of stitches of a thread. The fiber preform is capable of being pre-formed into a three-dimensional shape. The fiber preform along with a sheet of preformed thermoset resin that impregnates at least a portion of the fiber preform forms a composite material. The fiber preform reinforces areas of stress concentration of a core to form a vehicle component.

Abstract: A fiber preform for use in an overmolding process is provide that includes a fiber bundle arranged in a predetermined pattern and attached to itself with thread stitches to form at least one preform layer. At least one intumescent material is associated with the at least one preform layer. A vehicle component having fire resistant characteristics is also provided that includes a housing having a first side and a second side. The housing has a shape that defines the vehicle component. An intumescent material is provided on at least one of the first side and the second side of the housing.

Abstract: Flame resistant fabrics are provided that exhibit improved protection from molten metal spills, metal splatter, electric arc, and related thermal hazards illustratively including open flame and radiant heat. The flame resistant fabrics are made from a combination of cellulosic fibers and thermoplastic fibers, where the flame resistant fabric forms a char layer that does not become brittle when contacted by molten metal, metal splatter, electric arc, and related thermal hazards. By not becoming brittle the likelihood of break out of the fabric is minimized, thereby improving the level of protection to the user. As a result, the flame resistant fabric retains the desirable properties of fibers formed of organic materials in terms of comfort, weight, and durability.

Abstract: A fiber preform is provided for use in an overmolding process that includes a fiber bundle arranged in a predetermined pattern and attached to itself by a plurality of stitches of a thread to form at least one preform layer. At least one positioning element is associated with the at least one preform layer, the at least one positioning element configured to engage with at least one corresponding alignment element on a mold to indicate proper positioning of the fiber preform within the mold. A process of overmolding is also provided in which the at least one positioning element of the fiber preform engages with the at least one corresponding alignment element on the mold to indicate proper positioning. The mold cavity is then filled with a resin to permeate the fiber preform engaging the mold in a unique orientation to yield an article upon resin cure.

Abstract: A form for a vehicle component including a commingled fiber bundle laid out in a two-dimensional base layer that defines a shape of the form, a successive layer formed with the commingled fiber bundle in contact with the two-dimensional layer, and at least one of electrical conductive wiring, sensor, light emitting diode (LED), antenna, radio frequency identification chip, or a printed circuit board stitched to the successive layer. The comingled fiber bundle is composed of a reinforcement fiber being glass fibers, aramid fibers, carbon fibers, or a combination thereof.

Abstract: A fiber preform includes a substrate. A fiber bundle includes reinforcing fibers arranged on the substrate in a shape of a shoe sole and attached to the substrate by a plurality of stitches of the thermoplastic thread to form a first preform layer having a principal orientation. An orthotropic composite material shoe sole is also provided that includes the fiber preform with a cured molded resin surrounding the fiber preform, the cured molded resin having a shape of the shoe sole. A method of forming a fiber preform for use in a composite material shoe sole is also provided.

Abstract: A method of manufacturing comingled yarn of carbon and thermofusible fibres comprises the steps of: feeding a tow of thermofusible fibres from a spool to a blending roller and between the spool and the blending roller, spreading the thermofusible tow; feeding a tow of carbon fibres from a spool to the blending roller; spreading the carbon fibre tow between the spool and the blending roller by applying a flow of air over the tow to urge the tow against a supporting surface over which the carbon fibres pass on their way to the blending roller; combining the thermofusible and carbon fibre tows at the blending roller.

Abstract: A zip slider has: a slider body having upper and lower elements providing two entry channels through which zip teeth pass and slider un/mating; a pull tab having a cam; a biasing spring having a locking prong and a follower surface bearing against the cam. The cam on the follower surface biases the tab into a closed position in which it lies against the upper element. When the tab is in a lifted position, the cam action on the follower surface raises the prong above the mated teeth, enabling relative motion of the teeth and body; when the tab is in the closed position, the prong bears against the teeth to prevent unwanted relative slider and teeth motion. The slider has a counter bias, acting between the upper element and the tab to apply a biasing force on the tab acting against the action of the cam and follower surface.

Abstract: A zip fastener comprises two opposing and mutually engageable rows of zip teeth each being mounted upon a respective stringer tape; first and second sliders movably mounted upon the teeth, each slider being movable forward along the teeth to cause interdigitation of the teeth thereby to fasten the zip and backwards to cause extradigitation and unfastening of the zip, the sliders being mounted on the teeth in opposing directions such that motion of the sliders towards and away from each other results in the same action (e.g. fastening or unfastening) on the zip teeth; a docking member, mounted upon the teeth and being movable along the teeth, the docking member being mounted between the two sliders; and each slider being engageable with the docking member thereby to fasten the zip.

Abstract: A zip includes: a pair of stringer tapes, each of which supports a row of teeth; the teeth on the two tapes being mutually opposing and capable of interdigitation thereby to fasten one stringer tape to another; a slider, adapted to move along and whose motion is guided by the rows of teeth, the slider being adapted to cause interdigitation of the teeth as a result of motion along the teeth in a first direction, and to disconnect the teeth by motion along the teeth in a second direction; wherein the first and second stringer tapes are formed of a matrix of threads interspersed with a waterproof material.

Abstract: A garment has: a pair of fabric panels each connected to a zip tape; the zip tape including a pair of rows of zip teeth; a zip slider, having a bridge extending upwardly and a pull tab connected to the bridge via an intermediate link; the zip slider being movable along the zip tape to interdigitate the rows of zip teeth by pulling of the pull tab; the panels provide a pair of lips extending over the zip teeth thereby to cover the slider; the intermediate link, pull tab and bridge are constructed so that rotation of the pull tab causes the intermediate link to bear against outer surfaces of the bridge.

Abstract: A zip slider has: a slider body having upper and lower elements providing two entry channels through which zip teeth pass and slider un/mating; a pull tab having a cam; a biasing spring having a locking prong and a follower surface bearing against the cam. The cam on the follower surface biases the tab into a closed position in which it lies against the upper element. When the tab is in a lifted position, the cam action on the follower surface raises the prong above the mated teeth, enabling relative motion of the teeth and body; when the tab is in the closed position, the prong bears against the teeth to prevent unwanted relative slider and teeth motion. The slider has a counter bias, acting between the upper element and the tab to apply a biasing force on the tab acting against the action of the cam and follower surface.

Abstract: A zip slider comprises: a body (200) having two channels through which opposing rows of zip teeth may be respectively fed into a single channel in which the zip teeth are forced into interdigitation; upper and lower jaw members (114, 140) mounted on the body (200) and defining a slot between them; a biasing member (180), pivotally mounted on the body (200), and being pivotable in a first direction between a rest position and a deflected position, wherein pivoting of the biasing member (180) out of the rest position permits insertion of a loop of a pull tab into the jaws (114, 140) and, in the rest position, the biasing member (180) prohibits removal of the pull tab from the jaws (114, 140).

Abstract: There is disclosed a method for preparing a color chart comprising the steps of defining a reference color, specifying a range of colors from said reference color, each color being spaced by integral multiples of a preselected color difference value from any other color, the range spanning the color space between the reference color and some other color.

Abstract: A method for making a dye mixture to produce a target colour on a given substrate, comprising the steps of: ?a) measuring reflectance values RT(?i) of the target colour at a plurality of wavelengths ?i=1, 2 . . . n; b) measuring reflectance values Rs (?i) of the substrate at the same wavelengths ?i; forming a set of concentrations cj of M dyes in the calculated concentrations; the database having been compiled by aa) making dyeings of combinations of the dyes Dn at different concentrations; bb) measuring the reflectance values R of the dyeings at different wavelengths; cc) defining a function f(R); dd) defining a relationship between f(R) and c involving constants g and k; and ee) for each dye Dn determining constants gn, kn, such that the calculated values for f(R), c, gn kn approximate closely the measured values.