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 system and method for molding a fiber reinforced composite part are disclosed. The system includes a mold with electrical contacts that make electrical contact with at least one monitoring circuit incorporated in a fiber preform disposed in the mold so that the resistance of the monitoring circuit can be monitored as resin fills the mold cavity and envelopes the preform. The method includes monitoring the resistance of at least one monitoring circuit incorporated into a fiber preform disposed in a mold to determine the location of the resin flow front as resin is injected into the mold and surrounds the fiber preform.

Abstract: A method for fabricating a composite panel comprising stitching a plurality of first continuous reinforcing fibers in N first zones and M second zones of a backing substrate of a preform. The N first zones are arranged near C corners of the composite panel, where C is an integer. The plurality of first continuous reinforcing fibers in the N first zones is arranged radially relative to the C corners. At least one of a fiber density of the plurality of first continuous reinforcing fibers in the N first zones that is less than a fiber density of the plurality of first continuous reinforcing fibers in the M second zones, and a stitch density of the plurality of first continuous reinforcing fibers in the N first zones that is less than a stitch density of the plurality of first continuous reinforcing fibers in the M second zones.

Abstract: A method for fabricating a composite panel comprising stitching a plurality of first continuous reinforcing fibers in N first zones and M second zones of a backing substrate of a preform. The N first zones are arranged near C corners of the composite panel, where C is an integer. The plurality of first continuous reinforcing fibers in the N first zones is arranged radially relative to the C corners. At least one of a fiber density of the plurality of first continuous reinforcing fibers in the N first zones that is less than a fiber density of the plurality of first continuous reinforcing fibers in the M second zones, and a stitch density of the plurality of first continuous reinforcing fibers in the N first zones that is less than a stitch density of the plurality of first continuous reinforcing fibers in the M second zones.

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 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: 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 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 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: Collar support assemblies are provided. For example, a collar support assembly for an airfoil comprises a collar that includes a first surface shaped complementary to a fillet of the airfoil and a planar second surface. The first surface is disposed adjacent the fillet of the airfoil. The collar support assembly further comprises a shim material disposed between the second surface and an airfoil support structure and a filler material inserted between the first surface and the fillet of the airfoil to provide a tight fit between the collar and the airfoil. In other embodiments, the collar support assembly comprises a pair of collars and supports an airfoil doublet. The airfoil doublets may be part of an outlet guide vane assembly of a gas turbine engine, and methods for assembling outlet guide vane assemblies also are provided.

Abstract: Collar support assemblies are provided. For example, a collar support assembly for an airfoil comprises a collar that includes a first surface shaped complementary to a fillet of the airfoil and a planar second surface. The first surface is disposed adjacent the fillet of the airfoil. The collar support assembly further comprises a shim material disposed between the second surface and an airfoil support structure and a filler material inserted between the first surface and the fillet of the airfoil to provide a tight fit between the collar and the airfoil. In other embodiments, the collar support assembly comprises a pair of collars and supports an airfoil doublet. The airfoil doublets may be part of an outlet guide vane assembly of a gas turbine engine, and methods for assembling outlet guide vane assemblies also are provided.

Abstract: The invention provides compositions for controlled delivery and/or containment of therapeutic and/or diagnostic agents comprising the agent or agents encapsulated by a matrix containing chitosan, polyethylene glycol (PEG) and/or polyvinyl alcohol (PVA), and tetra-methoxy-ortho-silicate (TMOS) or tetra-ethoxy-ortho-silicate (TEOS), as well as methods for preparing the compositions, and uses of the compositions for therapy and imaging.