Abstract: The present invention relates to low or zero-tack composite materials such as pre-pregs and their use in automated manufacturing, particularly robotic pick and place. The present invention further relates to an automated process for preparing an article, particularly a molded article, from a fiber-reinforced composition material. The molded articles prepared by the process described herein are particularly suitable as components for transport applications, and particularly the automotive industry. The automotive components prepared by the present invention are particularly suitable as mid- or high-volume automotive parts, in which cost and speed of production are paramount. The present invention provides a process in which the cutting and handling of pre-preg materials is greatly simplified, providing advantages of efficiency and economy.

Abstract: Curative fibre components comprise one or more fibres for filaments of curative suitable to cure curable resins such as thermoset resin. In curative fibre components comprising a plurality of fibres of curative, the fibres can be commingled, such as twisting, to form a thread or yarn. Curative fibre components can be used to form a material in the form of a sheet, fabric, layer, textile or mat of woven or non-woven curative fibres. Curative fibre components can be used to produce composite materials such as fibre reinforced resinous composite materials. The curative fibre components can be commingled, including interwoven, stitched and layered with other fibres or fibrous materials, such as fibrous reinforcement, fibrous curable resin, fibrous thermoplastic, other non-reinforcing fibres to form composite materials, prepregs, preforms and articles.

Abstract: The present invention relates to low or zero-tack composite materials such as pre-pregs and their use in automated manufacturing, particularly robotic pick and place. The present invention further relates to an automated process for preparing an article, particularly a moulded article, from a fibre-reinforced composition material. The moulded articles prepared by the process described herein are particularly suitable as components for transport applications, and particularly the automotive industry. The automotive components prepared by the present invention are particularly suitable as mid- or high-volume automotive parts, in which cost and speed of production are paramount. The present invention provides a process in which the cutting and handling of pre-preg materials is greatly simplified, providing advantages of efficiency and economy.

Abstract: The present invention relates to thermoset resin fiber components, composite materials including thermoset resin fiber components, composite articles manufactured using such composite materials and methodologies for manufacturing same. The thermoset resin fiber components may include a single fiber of thermoset resin or a plurality of fibers commingled together. The properties and characteristics of the thermoset resin used are chosen according to the material to be produced therefrom. The thermoset fiber components may be woven into reinforcement fibers to form prepregs. Thermoplastic fibers may be commingled and co-woven with the thermoset fiber components.

Abstract: A tool for use in forming moulded articles, the tool comprising a tool body formed of a foamed material, a resinous material on the tool body and elastomeric material between said tool body and resinous material to inhibit the movement of resin from the resinous material into the tool body. The invention also provides a method of manufacturing a tool, a method of moulding articles using such a tool, and elastomeric material for use in forming a tool. One particular application of the tools of the present invention is in the formation or manufacture of moulded articles using curable, resinous composite materials.

Abstract: The present invention relates to thermoset resin fibre components, composite materials including thermoset resin fibre components, composite articles manufactured using such composite materials and methodologies for manufacturing same. The thermoset resin fibre components may include a single fibre of thermoset resin or a plurality of fibres commingled together. The properties and characteristics of the thermoset resin used are chosen according to the material to be produced therefrom. The thermoset fibre components may be woven into reinforcement fibres to form prepregs. Thermoplastic fibres may be commingled and co-woven with the thermoset fibre components.

Abstract: The present invention relates to thermoset resin fiber components, composite materials including thermoset resin fiber components, composite articles manufactured using such composite materials and methodologies for manufacturing same. The thermoset resin fiber components may include a single fiber of thermoset resin or a plurality of fibers commingled together. The properties and characteristics of the thermoset resin used are chosen according to the material to be produced therefrom. The thermoset fiber components may be woven into reinforcement fibers to form prepregs. Thermoplastic fibers may be commingled and co-woven with the thermoset fiber components.

Abstract: Curative fibre components comprise one or more fibres for filaments of curative suitable to cure curable resins such as thermoset resin. In curative fibre components comprising a plurality of fibres of curative, the fibres can be commingled, such as twisting, to form a thread or yarn. Curative fibre components can be used to form a material in the form of a sheet, fabric, layer, textile or mat of woven or non-woven curative fibres. Curative fibre components can be used to produce composite materials such as fibre reinforced resinous composite materials. The curative fibre components can be commingled, including interwoven, stitched and layered with other fibres or fibrous materials, such as fibrous reinforcement, fibrous curable resin, fibrous thermoplastic, other non-reinforcing fibres to form composite materials, prepregs, preforms and articles.

Abstract: A curable resinous material, and a method of manufacturing same, the curable resinous material comprising a resinous matrix material (R) with thermoplastic material (TP) distributed therein, some of said thermoplastic material (TP) being substantially fully dissolved in the matrix resin material (R) with other of the thermoplastic materials (TP) being only partially dissolved within the matrix material (R) when the resinous material is cured. The invention also provides a curable resinous material, and a method of manufacturing same, comprising a resinous matrix material (R) and a thermoplastic material (TP) distributed within the resinous matrix material (R) so that at least some of said thermoplastic material (TP) remains partially undissolved in the resinous matrix material (R) when cured.

Abstract: The present invention relates to thermoset resin fibre components, composite materials comprising thermoset resin fibre components, composite articles manufactured using such composite materials and methodologies for manufacturing same. The thermoset resin fibre components may comprise a single fibre of thermoset resin or a plurality of fibres commingled together. There properties and characteristics of the thermoset resin used are chosen according to the material to be produced therefrom. The thermoset fibre components may be woven into reinforcement fibres to form prepregs. Thermoplastic fibres may be commingled and co-woven with the thermoset fibre components.

Abstract: A method of manufacturing a composite and of securing a metallic coating to a resin-based composite material, comprising the provision of a keying structure on a metallic electroplated preform and bringing the keying structure and the composite material together under conditions to cause the composite material and the keying structure to interlock. The invention also provides a composite comprising a resin-based composite material with a metallic coating on a surface, or part surface thereof, the metallic coating comprising an outer electroplated preform, and an inner keying structure which is located generally between said electroplated preform and the composite material to provide attachment of the electroplated preform on the composite material.

Abstract: A tool for use in forming moulded articles, the tool comprising a tool body formed of a foamed material, a resinous material on the tool body and elastomeric material between said tool body and resinous material to inhibit the movement of resin from the resinous material into the tool body. The invention also provides a method of manufacturing a tool, a method of moulding articles using such a tool, and elastomeric material for use in forming a tool. One particular application of the tools of the present invention is in the formation or manufacture of moulded articles using curable, resinous composite materials.

Abstract: A moulding material comprising a fibrous layer carrying resinous material to have at lest one area of relatively high resin content and at least one other area of relatively low resin content defined on a surface of the fibrous layer such that upon curing or partial curing resin from the said relatively high resin content area(s) moves over the relatively low resin content area(s) to provide a substantially even distribution of resin between the areas.