Abstract: A thermoplastic thermoformable composite material for shaping and stretching into a desired form without voids and holes, including a core formed by at least one layer of chopped fibers enveloped and impregnated by thermoplastic material to form a fabric layer. Layers of thermoplastic material respectively positioned on opposite sides of the fabric layer core, and the layers of thermoplastic material provided with a sufficient thickness to flow into and heal any voids or holes formed in the core as the composite material is shaped and stretched into a desired form.

Abstract: A thermoplastic thermoformable composite material for shaping and stretching into a desired form without voids and holes, including a core formed by at least one layer of chopped fibers enveloped and impregnated by thermoplastic material to form a fabric layer. Layers of thermoplastic material respectively positioned on opposite sides of the fabric layer core, and the layers of thermoplastic material provided with a sufficient thickness to flow into and heal any voids or holes formed in the core as the composite material is shaped and stretched into a desired form.

Abstract: A thermoplastic resin defines a core of a thermoformable thermoplastic composite material. The core is sufficiently thick to provide for a shaping of the composite material at an elevated temperature to any desired configuration. First and second layers of fabric material are disposed on opposite sides of the core. The fabric material may be formed of glass, carbon or aramid and may be formed from woven fibers, unidirectional or chopped fibers or random strand mats. The fabric layers have a thickness sufficient to impart strength and rigidity to the fabric material. Layers of a thermoplastic thermoformable resin material may be disposed on the layers of the fabric material. The thermoplastic layers impregnate the fabric layers, bond the fabric layers to the core and provide a smooth external surface to the composite material.

Abstract: A thermoplastic composite material may be formed by supplying the thermoplastic material to the opposite surfaces of the fabric material and by then passing the resultant material through the spaces between progressive pairs of rollers. The rollers in each progressive pair have a decreased spacing relative to the rollers in the previous pair so as to squeeze the thermoplastic material into the interstices between the fabric threads without compressing the fabric material. The resultant material may also be moved in a tortuous path, such as formed by a pair of rollers defining an S-configuration relative to the resultant material, to engage the opposite surfaces of the resultant material and squeeze air from the resultant material without compressing the fabric.

Abstract: A thermoplastic resin defines a core of a thermoformable thermoplastic composite material. The core is sufficiently thick to provide for a shaping of the composite material at an elevated temperature to any desired configuration. First and second layers of fabric material are disposed on opposite sides of the core. The fabric material may be formed of glass, carbon or aramid and may be formed from woven fibers, unidirectional or chopped fibers or random strand mats. The fabric layers have a thickness sufficient to impart strength and rigidity to the fabric material. Layers of a thermoplastic thermoformable resin material may be disposed on the layers of the fabric material. The thermoplastic layers impregnate the fabric layers, bond the fabric layers to the core and provide a smooth external surface to the composite material.

Abstract: A thermoformable thermoplastic composite material has a core sufficiently thick to provide for a shaping of the composite material at an elevated temperature to any desired configuration. Layers of a fabric material disposed on opposite sides of the core may be formed of glass, carbon or aramid and from woven fibers, unidirectional or chopped fibers or random strand mats. The fabric layers are sufficiently thick to impart strength and rigidity to the composite material. Layers of a thermoplastic thermoformable resin material may be disposed on the fabric layers. The thermoplastic layers impregnate the fabric layers, bond the fabric layers to the core and provide a smooth external surface to the composite material. The core is preferably thinner than the combined thicknesses of the fabric layers and the thermoplastic layers. For example, the thickness of each fabric layer may be 0.008"-0.009", of each thermoplastic layer may be 0.0005"-0.002" and of the thermoplastic composite material may be 0.035"-0.060".

Abstract: A thermoplastic resin defines a core of a thermoformable thermoplastic composite material. The core is sufficiently thick to provide for a shaping of the composite material at an elevated temperature to any desired configuration. First and second layers of fabric material are disposed on opposite sides of the core. The fabric material may be formed of glass, carbon or aramid and may be formed from woven fibers, unidirectional or chopped fibers or random strand mats. The fabric layers have a thickness sufficient to impart strength and rigidity to the fabric material. Layers of a thermoplastic thermoformable resin material may be disposed on the layers of the fabric material. The thermoplastic layers impregnate the fabric layers, bond the fabric layers to the core and provide a smooth external surface to the composite material.

Abstract: A thermoformable thermoplastic composite material has a core sufficiently thick to provide for a shaping of the composite material at an elevated temperature to any desired configuration. Layers of a fabric material disposed on opposite sides of the core may be formed of glass, carbon or aramid and from woven fibers, unidirectional or chopped fibers or random strand mats. The fabric layers are sufficiently thick to impart strength and rigidity to the composite material. Layers of a thermoplastic thermoformable resin material may be disposed on the fabric layers. The thermoplastic layers impregnate the fabric layers, bond the fabric layers to the core and provide a smooth external surface to the composite material. The core is preferably thinner than the combined thicknesses of the fabric layers and the thermoplastic layers. For example, the thickness of each fabric layer may be 0.008"-0.009" of each thermoplastic layer may be 0.0005"-0.002" and of the thermoplastic composite material may be 0.035"-0.060".

Abstract: A thermoplastic thermoformable resin material defines a core of a thermoformable thermoplastic composite material. First and second layers of fabric material are disposed against opposite sides of the core. An additional layer of a fabric material is positioned on the first fabric layer to impart a particular color to the composite material. A resin envelopes and impregnates the different fabric layers and bonds these layers to the core. The fabric layers have a total thickness sufficient to impart strength and rigidity to the fabric material. The core is sufficiently thick to provide for a shaping of the composite material at an elevated temperature to any desired configuration without any rippling or buckling of the composite material. Additional layers of a thermoplastic thermoformable resin material may be disposed on the outer layers of the fabric material. They impregnate the fabric layers, provide a continuity with the core and provide a smooth external surface to the composite material.

Abstract: A thermoplastic composite having a plurality of layers of material each having a particular total thickness and a particular total volume, including a first layer of thermoplastic resin materal forming a core. At least two layers of fabric material each disposed on an opposite side of the first layer and impregnated with the core material to define an outer skin on the core. Two layers of thermoplastic resin material each overlaying one of the at least two layers of fabric and each bonded to the thermoplastic material impregnated in the adjacent layer of fabric material to define an outer covering for protecting the layers of fabric and providing a covering for protecting the layers of fabric and providing a smooth exterior. The thickness of the core forming a substantial percentage of the total thickness of the composite and the fiber volume of the at least two layers of fabric material forming less than one third (1/3) of the total volume of the composite.

Abstract: This disclosure teaches a method of making a silicon carbide article of less than full density. A mixture of silicon carbide particles, silicon particles and a thermosetting polymeric material are molded to form an article as a green body. The green body is pyrolyzed to change the polymer into carbon and the carbon is then changed into silicon carbide by the silicon contained in the mixture.