Abstract: A method of producing a non-crimp fabric and a non-crimp fabric comprising a layup of fabric plies stitched together by a thread, at least part of which is fusible, is provided. The method can include heating the stitched plies to soften or melt the fusible thread. The use of fusible thread can act as an in situ binder within the non-crimp fabric and tension created by the unfused stitching may create channels for matrix resin infusion during manufacture.

Abstract: A method of producing a non-crimp fabric and a non-crimp fabric comprising a layup of fabric plies stitched together by a thread, at least part of which is fusible, is provided. The method can include heating the stitched plies to soften or melt the fusible thread. The use of fusible thread can act as an in situ binder within the non-crimp fabric and tension created by the unfused stitching may create channels for matrix resin infusion during manufacture.

Abstract: This invention relates to a composite laminate, a layup and preform for such a composite laminate and to a method of manufacturing the composite laminate. The layup (28), preform and composite laminate (22) include at least one ply (20) which includes hairy yarn (10). The action of the hairy yarn (10) is to provide cross ply linking owing to the extension of fibers from the hairy yarn into spaces both within the ply and between the plies. The addition of resin matrix material (26) to layup provides a firm cross ply linkage to the composite laminate.

Abstract: The present invention relates to a method of bonding together two pieces of composite material (10, 26) by applying a layer of glass fibre (20, 28) to a surface of each piece of composite material 10, 26, and bonding the pieces together by means of adhesive (30) between the layers of glass fibre (10, 26). The inclusion of the glass fibre layers (20, 28) advantageously promotes failure of the bond adjacent the glass fibre-adhesive interface rather than at the glass fibre-composite material interface, with the result that damage to the composite material (10, 26) is minimised, and subsequent repair is made easier.

Abstract: A method of producing a non-crimp fabric (10) and a non-crimp fabric comprising a layup of fabric plies (12) stitched together by a thread (18), at least part of which is fusible, is provided. The method can include heating the stitched plies (12) to soften or melt the fusible thread (18). The use of fusible thread (18) can act as an in situ binder within the non-crimp fabric (10) and tension created by the unfused stitching may create channels for matrix resin infusion during manufacture.

Abstract: The method comprises positioning two components adjacent each other so as to define a space between them, bridging edges of the space with webs and filling the space with flowable material such as adhesive. A fabric is preferably arranged in the space and is impregnated by the flowable material as it is drawn into the space.

Abstract: A method of manufacturing a composite laminate and a composite laminate manufactured according to the method are provided. The laminate comprises a series of fabric plies (1 to 15) of fibrous reinforcing material set in plastics matrix material. The method includes the steps of providing a relatively small number of fabric styles from which to choose; selecting at least one of those fabric styles according to design requirements for a particular portion of the laminate; laying up that portion with the said selection, and repeating the selection and layup steps as required to complete the layup of the laminate.

Abstract: A composite laminate, an aircraft skin panel, an airfoil, an aircraft and a method of manufacturing such a composite laminate are provided. The laminate includes at least three layers, namely a first layer of fiber reinforced composite material, a second layer usually metallic and usually forming a surface of the component and a third layer of impact energy-absorbing material interposed between the first and second layers, wherein the second and third layers protect the first layer from impact damage. The method of manufacture involves placing all three layers, including a said third layer of foaming adhesive, in a closed mould and foaming the adhesive to form a component to shape.