Abstract: A process for aligning discontinuous fibers, and composite products and mats comprised of highly aligned discontinuous fibers, including products of the process. Aligned discontinuous fiber composite products include a matrix of fibers, each fiber having a longitudinal fiber axis, the composite comprising a free, uncut edge extending along an edge axis. The longitudinal fiber axis of a majority of the fibers in the composite product are aligned within a predetermined alignment tolerance of an alignment axis non-parallel to the edge axis. Aligned discontinuous fiber mats may have a first areal density of fibers in a first region of the composite located inward relative to the free, uncut edge, and a second area density at or adjacent to the free, uncut edge.

Abstract: A process for aligning discontinuous fibers, and composite products and mats comprised of highly aligned discontinuous fibers, including products of the process. Aligned discontinuous fiber composite products include a matrix of fibers, each fiber having a longitudinal fiber axis, the composite comprising a free, uncut edge extending along an edge axis. The longitudinal fiber axis of a majority of the fibers in the composite product are aligned within a predetermined alignment tolerance of an alignment axis non-parallel to the edge axis. Aligned discontinuous fiber mats may have a first areal density of fibers in a first region of the composite located inward relative to the free, uncut edge, and a second area density at or adjacent to the free, uncut edge.

Abstract: A system and method for aligning discontinuous fibers, manufacturing tailored preforms, and composite materials comprised of highly aligned discontinuous fibers.

Abstract: A system and method for aligning discontinuous fibers, manufacturing tailored preforms, and composite materials comprised of highly aligned discontinuous fibers.

Abstract: The improved footwear system of the present application uses composite materials in the design of an advanced modular in-shoe foot orthosis and a new container assembly which includes a high performance energy storage and return element orthosis. The footwear system uses a method of manufacture incorporating a new last model. The advantages of the footwear system over standard issue combat boots include lower weight, improved treatment of lower extremity overuse injuries and reduction of the occurrence of such overuse injuries by protecting at-risk feet with advanced footwear which can be customized to meet the biomechanical needs as well as the specific activities of the wearer.

Abstract: A system for use in monitoring a structure is provided. The system includes a strip of piezoresistive material including nano-elements, electrodes coupled to the strip, and a resistance detector configured to measure a resistance of the strip.

Abstract: The improved footwear system of the present application uses composite materials in the design of an advanced modular in-shoe foot orthosis and a new container assembly which includes a high performance energy storage and return element orthosis. The footwear system uses a method of manufacture incorporating a new last model. The advantages of the footwear system over standard issue combat boots include lower weight, improved treatment of lower extremity overuse injuries and reduction of the occurrence of such overuse injuries by protecting at-risk feet with advanced footwear which can be customized to meet the biomechanical needs as well as the specific activities of the wearer.

Abstract: A woven ballistic resistant fabric armor system comprising at least one ply having a yarn-yarn angle between the warp and fill yarns of less than 90°, with each ply oriented relative to an axis along the thickness of the plies such that adjacent plies have a different yarn-yarn angle, a different orientation, or both. The armor system may feature materials of different stiffness, strength, and strain-to-failure in each ply or a filler between selected plies, including a filler comprising discrete pieces of fabric ply that fit within the cell periphery of a stitching pattern.

Abstract: A method and apparatus for forming laminate composite structures. At least two laminae, each containing electrically conductive reinforcing fibers, are placed upon each other in contacting relationship to form a generally layered structure. The layered structure may be subjected to heat to conductively transfer heat through the layered structure and thereby improve the surface contact between the two laminae. The layered structure is volumetrically heated by inductively transferring energy to the electrically conductive reinforcing fibers. The heated, layered structure is consolidated, such as by applying pressure and reducing the temperature of the layered structure. The consolidated structure is then quenched by rapidly cooling the consolidated structure in a directionally controlled manner about a midplane thereof.

Abstract: A process for continuous composite coextrusion comprising: (a) forming first a material-laden composition comprising a thermoplastic polymer and at least about 40 volume % of a ceramic or metallic particulate in a manner such that the composition has a substantially cylindrical geometry and thus can be used as a substantially cylindrical feed rod; (b) forming a hole down the symmetrical axis of the feed rod; (c) inserting the start of a continuous spool of ceramic fiber, metal fiber or carbon fiber through the hole in the feed rod; (d) extruding the feed rod and spool simultaneously to form a continuous filament consisting of a green matrix material completely surrounding a dense fiber reinforcement and said filament having an average diameter that is less than the average diameter of the feed rod; and (e) depositing the continuous filament into a desired architecture which preferably is determined from specific loading conditions of the desired object and CAD design of the object to provide a green fiber rei

Abstract: A method and apparatus for forming laminate composite structures. At least two laminae, each containing electrically conductive reinforcing fibers, are placed upon each other in contacting relationship to form a generally layered structure. The layered structure may be subjected to heat to conductively transfer heat through the layered structure and thereby improve the surface contact between two laminae. The layered structure is volumetrically heated by inductively transferring energy to the electrically conductive reinforcing fibers. The heated, layered structure is consolidated, such as by applying pressure and reducing the temperature of the layered structure. The consolidated structure is then quenched by rapidly cooling the consolidated structure in a directionally controlled manner about a midplane thereof.

Abstract: The present invention comprises a dynamic interphase-loading apparatus and method for testing the interfacial shear strength, stress-strain response, energy absorbing capability and durability of an interphase region of a fiber/matrix composite under quasi-static to high strain rates. The apparatus provides a load to the fiber/matrix interphase under high loading rates. The apparatus includes means for continuously monitoring the load applied to the fiber/matrix composite and providing a signal representative thereof, and means for monitoring the displacement of the interphase and providing a signal representative thereof. The apparatus further includes a computer that receives the load signal and the displacement signal, and generates chemical properties of the interphase of the fiber/matrix composite.

Abstract: Mesh susceptors for use in induction heating and bonding processes are tailored to obtain more uniform heating across the susceptor and hence, the bondline, when bonding composite parts. The susceptors are tailored by cutting and removing segments from the mesh areas where the induced current and hence, heat generation, is highest. An algorithm is employed to predict the induced current patterns throughout the mesh so that areas of high heat generation can be identified and then cut and removed. In this way, essentially uniform temperatures in metal mesh susceptors may be achieved by specifically designed cut patterns within the mesh even though the mesh susceptor is subject to non-uniform magnetic fields.

Abstract: This invention is a new process to promote adhesion between thermoplastic polymers and thermosetting resin adhesives. This is accomplished by selecting a third "interlayer" polymer which is compatible with both the thermoplastic and thermoset polymers. This compatible interlayer is incorporated with the thermoplastic polymer during fabrication to provide the finished part surface with a layer of the compatible film. Upon adhesive bonding, diffusion of the thermosetting adhesive molecules into the compatible film occurs before complete cure, or hardening of the thermosetting adhesive. After completion of cure an Interpenetrating Network (IPN) is formed. Molecular entanglement in this network provides superior adhesive strength enhancement.

Abstract: A design for a high damping composite joint which dissipates vibrations through the use of air gaps and viscoelastic material minimizing the transfer of vibrations to the metallic coupling. Viscoelastic material is used with adhesive to provide for increased energy dissipation by the joint. As the load increases on the joint, the load transfers from adhesive to the viscoelastic. The viscoelastic begins to take the load of the joint at the point where the adhesive becomes plastic. Acoustic vibrations are then dissipated in the viscoelastic and are prevented from being transferred to the metallic coupling by air gaps provided in the joint. The amount of viscoelastic and adhesive used depends on the anticipated load. Finite element analysis is used to calculate optimal amounts of viscoelastic and adhesive.