Abstract: A deformable, coated radius filler composed of a continuous or elongated fibrous structure and a tacky, resin surface coating formed by pulling a dry, continuous or elongated fibrous structure through a heated resin bath. The coated radius filler has an inner portion that is substantially free of resin and the resin surface coating has a substantially uniform thickness.

Abstract: Prepreg tapes suitable for automated placement process are formed by slitting a sheet of partially impregnated prepreg. The partially impregnated prepreg is composed of unidirectional fiber tows partially embedded in a resin layer and has a continuous resin surface only on one side. In some embodiments, one or two nonwoven veil(s) is/are incorporated into the partially impregnated prepreg.

Abstract: The present disclosure relates to a stitching yarn and non-crimp fabrics containing such yarn. The stitching yarn described herein is a multifilament stitching yarn characterized by two or more of the following properties: (a) comprises a plurality of polymeric fibers, (b) has a linear density of less than or equal to 80 dtex, (c) has a filament count of less than or equal to 0.8 times the dtex value of the stitching yarn, or (d) has a twist of less than 200 revolutions per meter (r/m). The present disclosure also relates to a fiber preform, composite material, and composite article containing the non-crimp fabric.

Abstract: A liquid binder composition for binding fibrous materials in the fabrication of resin-infusible preform is disclosed. The binder composition is an aqueous dispersion containing (a) one or more multifunctional epoxy resins, (b) at least one thermoplastic polymer, (c) one or more surfactants selected from anionic surfactants, nonionic surfactants, and combinations thereof, (d) water, and is essentially free of organic solvents. Also disclosed is an emulsification process for producing the liquid binder composition.

Abstract: A dry, fibrous tape for use in an automated placement process such as ATL or AFP and a preform produced therefrom. The preform is configured for resin infusion. The tape contains a layer of unidirectional fibers, at least one nonwoven veil bonded to one side of the fiber layer, and at least binding materials present within the tape. The preform produced from laying down such tape exhibits a low-bulk property that is close to the final thickness of the cured fiber-reinforced resin article and no further consolidation or compaction is required.

Abstract: Disclosed herein is a dry, self-supporting fibrous material, the fibers of which have been treated with a binder composition. The fibrous material can be slit into tapes or tows that are suitable for use in an Automated Tape Laying (ATL) or Automated Fiber Placement (AFP) process. This fibrous material is suitable for forming preforms which are configured to receive a matrix resin by resin infusion in the manufacturing of structural composite parts.

Abstract: A deformable, coated radius filler composed of a continuous or elongated fibrous structure and a tacky, resin surface coating formed by pulling a dry, continuous or elongated fibrous structure through a heated resin bath. The coated radius filler has an inner portion that is substantially free of resin and the resin surface coating has a substantially uniform thickness.

Abstract: A deformable, coated radius filler composed of a continuous or elongated fibrous structure and a tacky, resin surface coating formed by pulling a dry, continuous or elongated fibrous structure through a heated resin bath. The coated radius filler has an inner portion that is substantially free of resin and the resin surface coating has a substantially uniform thickness.

Abstract: Disclosed herein is a dry, self-supporting fibrous material, the fibers of which have been treated with a binder composition. The fibrous material can be slit into tapes or tows that are suitable for use in an Automated Tape Laying (ATL) or Automated Fiber Placement (AFP) process. This fibrous material is suitable for forming preforms which are configured to receive a matrix resin by resin infusion in the manufacturing of structural composite parts.

Abstract: A liquid binder composition for binding fibrous materials in the fabrication of resin-infusible preform is disclosed. The binder composition is an aqueous dispersion containing (a) one or more multifunctional epoxy resins, (b) at least one thermoplastic polymer, (c) one or more surfactants selected from anionic surfactants, nonionic surfactants, and combinations thereof, (d) water, and is essentially free of organic solvents. Also disclosed is an emulsification process for producing the liquid binder composition.

Abstract: A liquid binder composition for binding fibrous materials in the fabrication of resin-infusible preform is disclosed. The binder composition is an aqueous dispersion containing (a) one or more multifunctional epoxy resins, (b) at least one thermoplastic polymer, (c) one or more surfactants selected from anionic surfactants, nonionic surfactants, and combinations thereof, (d) water, and is essentially free of organic solvents. Also disclosed is an emulsification process for producing the liquid binder composition.

Abstract: Disclosed herein is a dry, self-supporting fibrous material, the fibers of which have been treated with a binder composition. The fibrous material can be slit into tapes or tows that are suitable for use in an Automated Tape Laying (ATL) or Automated Fiber Placement (AFP) process. This fibrous material is suitable for forming preforms which are configured to receive a matrix resin by resin infusion in the manufacturing of structural composite parts.

Abstract: Embodiments of the invention are directed to resin-soluble thermoplastic veils for use in liquid resin infusion processes, methods of manufacturing resin-soluble thermoplastic veils for use in liquid resin infusion processes, and methods of manufacturing composite articles using resin-soluble thermoplastic veils for use in liquid resin infusion applications. The resin-soluble thermoplastic veils according to embodiments of the invention and of which function as a toughening agent in composites having the veil incorporated therein have improved characteristics including, but not limited to, increased uniformity and decreased thickness relative to prior art veils. These characteristics translate into improvements in the processing of a composite article including, but not limited to, a substantial or complete elimination in premature dissolution of the veil during cure.

Abstract: A plurality of thermoplastic composite structures are laminated to each other in a lay-up arrangement to form a laminate. Each thermoplastic composite structure is composed of a core composite layer and a surface layer polymer applied to opposing surfaces of the core composite layer. The core composite layer is composed of a fibrous substrate and one or more high performance polymers, which crystallize at a faster rate than the surface layer polymer.

Abstract: Disclosed herein is a dry, self-supporting fibrous material, the fibers of which have been treated with a binder composition. The fibrous material can be slit into tapes or tows that are suitable for use in an Automated Tape Laying (ATL) or Automated Fiber Placement (AFP) process. This fibrous material is suitable for forming preforms which are configured to receive a matrix resin by resin infusion in the manufacturing of structural composite parts.

Abstract: Disclosed herein is a dry, self-supporting fibrous material, the fibers of which have been treated with a binder composition. The fibrous material can be slit into tapes or tows that are suitable for use in an Automated Tape Laying (ATL) or Automated Fiber Placement (AFP) process. This fibrous material is suitable for forming preforms which are configured to receive a matrix resin by resin infusion in the manufacturing of structural composite parts.

Abstract: A thermoplastic polymer toughening material in the form of polymeric fibers produced by mixing at least one epoxy curing agent and a thermoplastic polyaromatic polymer to form an admixture, and producing polymeric fibers from the admixture, wherein the thermoplastic polymer toughening material does not include an epoxy resin, and is soluble in an epoxy resin at a temperature lower than a dissolving temperature required by the thermoplastic polymer toughening material without epoxy curing agent.

Abstract: A thermoplastic polymer toughening material in the form of polymeric fibers produced by mixing at least one epoxy curing agent and a thermoplastic polyaromatic polymer to form an admixture, and producing polymeric fibers from the admixture, wherein the thermoplastic polymer toughening material does not include an epoxy resin, and is soluble in an epoxy resin at a temperature lower than a dissolving temperature required by the thermoplastic polymer toughening material without epoxy curing agent.

Abstract: A dry, fibrous tape for use in an automated placement process such as ATL or AFP and a preform produced therefrom. The preform is configured for resin infusion. The tape contains a layer of unidirectional fibers, at least one nonwoven veil bonded to one side of the fiber layer, and at least binding materials present within the tape. The preform produced from laying down such tape exhibits a low-bulk property that is close to the final thickness of the cured fiber-reinforced resin article and no further consolidation or compaction is required.

Abstract: Embodiments of the invention are directed to resin-soluble thermoplastic veils for use in liquid resin infusion processes, methods of manufacturing resin-soluble thermoplastic veils for use in liquid resin infusion processes, and methods of manufacturing composite articles using resin-soluble thermoplastic veils for use in liquid resin infusion applications. The resin-soluble thermoplastic veils according to embodiments of the invention and of which function as a toughening agent in composites having the veil incorporated therein have improved characteristics including, but not limited to, increased uniformity and decreased thickness relative to prior art veils. These characteristics translate into improvements in the processing of a composite article including, but not limited to, a substantial or complete elimination in premature dissolution of the veil during cure.