Abstract: A composite material assembly (1) comprises a) a surface enhancing layer (5) comprising at least one layer of fibers, having a length to width aspect ratio of more than 5:1 and b) a structural layer (7) comprising at least one reinforcing fiber and at least one polymeric matrix.

Abstract: The invention relates to a method for manufacturing a core composite (1, 20, 26) having a folded honeycomb core (2, 21, 29) provided on both sides with cover layers (3, 4, 22, 23, 27, 28) wherein the folded honeycomb core (2, 21, 29) has a number of drainage-enabling channels (5). First a core filler material (16, 17) is introduced into the folded honeycomb core (2, 21, 29) at least in some areas in order to provide the filler material with sufficient stability for the subsequent sewing process. The cover layers (3, 4, 22, 23, 27, 28) which are not yet impregnated with a curable plastics material are then placed on the folded honeycomb core (2, 21, 29) and stitched to this along the base lines (6 to 8) and/or apex lines (9, 10) at least in some sections by means of a sewing thread (19). The infiltration of the overall structure with a curable plastics material is then carried out followed by hardening by applying pressure and/or temperature.

Abstract: Formed building materials comprising a sequestered CO2 are provided. The building materials of the invention include a composition comprising a carbonate/bicarbonate component. Additional aspects of the invention include methods of making and using the formed building materials.

Abstract: A positioning member (11) for a tubular (10) is formed using a prefabricated fibre-reinforced resin shell (1) positioned upon a surface of the tubular and bonded to provide a protrusion upon the surface of the tubular. In a disclosed method a fibre-reinforced resin shell (1) is secured to an external surface of a tubular (10) thereby enclosing a cavity between the shell (1) and the surface of the tubular (10); a bonding agent is introduced through inlet ports (5) in a surface of the fibre- reinforced resin shell (1) to fill a cavity between the shell (1) and the surface of the tubular (10), and the bonding agent is cured.

Abstract: A leaf spring for a motor vehicle is made from a fiber composite component including individual fibers in form of at least two textile layers stacked on top of each other and a matrix made of a duroplastic or thermoplastic resin surrounding the fibers. The resin is hardened in a mold tool by applying pressure and heat. The stacked textile layers are formed inside a mold tool and fixed by a dry binder applied to at least one of the textile layers to form a dry preform. A fiber composite blank is stamped from the preform and subsequently infiltrated with the resin in a RTM cavity and hardened. The binder applied in dry form may only be arranged in certain areas of the textile layers.

Abstract: A method of manufacturing a composite element. A stack of plies is assembled on a lay-up table, each ply comprising a plurality of reinforcement elements such as dry-fibers. A first part of the stack of plies is bound to form a partially bound stack of plies, a second part of the stack of plies remaining unbound. The partially bound stack of plies is press-formed in a mold cavity between a pair of mold tools to form a shaped pre-form, plies in the second part of the stack sliding against each other during the press-forming. A liquid matrix material is injected into the shaped pre-form in the mold cavity and subsequently cured.

Abstract: A reinforcing part of ?-shaped section made out of composite material, and a method of making the part, the method including: making a first set of layers of interlinked yarns by three-dimensional weaving to form a first fiber blank portion to form a base preform; making a second set of layers of interlinked yarns by three-dimensional weaving to form a second fiber blank portion to form a stiffener preform, yarns of the second set being interlinked with yarns of the first set by weaving over a central interlinked strip that flares towards side edges of the first fiber blank portion in a zone corresponding to the step of the base; shaping the two fiber blank portions to obtain a single-piece fiber preform having a portion forming a base preform and a portion forming a stiffener preform; and depositing a resin in the fiber preform to form a matrix.

Abstract: Systems, tools, and methods for forming composite tubular stringers and stiffened composite structures having composite tubular stringers are disclosed. Systems include a tool, a supply of pliable blanks for forming composite tubular stringers with the tool, a supply of skin segments for forming a skin, and a layup mandrel for receiving the composite tubular stringers and the skin to form a stiffened composite structure. Tools include a wrapping mandrel for forming from a pliable blank a tubular structure with a first circumferential profile, and a transition mandrel for conforming the tubular structure to a second circumferential profile. Methods include wrapping a pliable blank around a wrapping mandrel to define a tubular structure having a first circumferential profile, and transitioning the tubular structure from having the first circumferential profile to having a second circumferential profile.

Abstract: A prepreg assembly comprising resin and fibers and comprising an uppermost curable resin surface layer such that when the assembly is cured, the uppermost surface layer has a sandability of at least 0.30 mg/cycle over 200 cycles, as measured according to ASTM D4060 using a Taber 5151 Abrasion Tester fitted with H18 wheels and a 1.0 kg weight is provided.

Abstract: Process for producing a ceramic composite structure includes impregnating a reinforcing material with a suitable precursor slurry composition including thermosetting resin, a suitable curing agent, a ceramic component, a carbonaceous solids component, and optionally, a suitable solvent. Exemplary thermosetting resins include polyesters, vinyl esters, epoxy resins, bismaleimide resins, and polyimide resins. The carbonaceous solids component provides a suitable amount of carbon char upon pyrolization. The preform may be dried prior to curing to remove solvents and thereby provide a working material comprising up to 70 volume % solids. The preform is cured, pyrolized, and infiltrated with molten silicon to form a composite article. The thermosetting resin is selected for processibility, green strength, and relatively fast cure cycle.

Abstract: Warps of a reinforcing filamentary yarn are selectively interwoven with wefts of the reinforcing filamentary yarn, so as to form a tailored woven reinforcement for use in the manufacture of a composite article having a known three-dimensional shape. The wefts extend in a direction transverse to said warps, to form at least one first portion of the woven reinforcement having interwoven warps and wefts, and to form at least one second portion of the woven reinforcement having other than interwoven warps and wefts. The at least one first portion and the at least one second portion are arranged, one relative to the other within said woven reinforcement, in dependence upon the known three-dimensional shape of the composite article. The woven reinforcement is suitable for use in a variety of processes including prepreg processes, Resin Transfer Molding processes and Resin Infusion Molding processes.

Abstract: A sports racquet having a plurality of string port holes and conventional string holes is formed of a single tube of prepreg material. When molded, mold elements press opposed portions of the prepreg tube into contact with one another, and shape the adjoining prepreg material into a string port hole blanks. The portion of the pressed-together material which initially blocks the string port hole is removed after molding so that the string port holes extend through the frame. Alternatively, the mold elements cause the prepreg tube to follow a serpentine shape, thereby defining string port holes which are open alternately along the top and bottom surface of the frame. A pair of cover rings may be secured to the top and bottom racquet surfaces to cover the open sides of the string port holes.

Abstract: A method is provided for producing a weight-reduced FRP cylinder which can attain high strength, and also such an FRP cylinder is provided. This FRP cylinder producing method, in which a plurality of prepregs formed by impregnating reinforced fibers with thermosetting resin sheets are wound into a cylinder and thermally cured to be formed as a plurality of FRP layers, includes a simultaneous multilayer winding process in which a torsional rigidity retaining prepreg and a buckling prevention prepreg are continuously wound a plurality of turns with being layered on each other when the plurality of prepregs are wound into a cylinder, wherein the torsional rigidity retaining prepreg includes a layer of fibers oblique to a cylindrical axis direction of the FRP cylinder, and wherein the buckling prevention prepreg includes a layer of fibers orthogonal to the cylindrical axis direction.

Abstract: A molding apparatus for manufacturing a wind turbine blade component includes a main mold body (30) and a flexible bladder (38). The main mold body includes a shape defining surface (32) for receiving composite material forming the blade component and a heat reservoir (40) for heating the blade component during curing. The flexible bladder overlays and conforms to the shape of the blade component and is configured to receive heated liquid for heating the blade component during curing. One or both of the main mold body and the flexible bladder is divided into a plurality of zones (58, 66) that are independently controlled by a controller (70) to maintain a generally uniform temperature of the blade component at each zone.

Abstract: Crimp-imbalanced fabric systems are accomplished by varying the levels of yarn crimp within a single fabric layer and across layers of a multi-layer fabric system. The method includes developing a crimp in the yarn (utilized for producing a fabric layer) by optionally pulling the yarn through a solution that substantially coats the yarn. The optionally removable coating has a thickness that ensures a proper amount of crimp in the yarn. The tension in the yarn is controlled; the yarn is weaved; and a crimp is applied in the yarn. Once the crimp is applied, families of the crimped yarn are utilized as a single layer or multiple layer system to increase performance attributes including enhanced energy absorption.

Abstract: A method of forming a drain fixture is disclosed along with the resulting structure. The method includes the steps of aligning two preformed fabrics on top of each other, with connecting elements positioned between the fabrics and bonded to each of the two fabrics, positioning the connected two fabrics in a mold and centering the connected fabrics inside the mold by means of the connecting elements, injecting a plastic material through openings in the connecting elements, and filling the space between the two fabrics with the plastic material.

Abstract: A method for the production of a hollow profile, which is a cockpit cross-member for a motor vehicle, involves braiding endless fibers around a core that forms the inner contour of the hollow profile to produce a fibrous hollow structure. After the braiding, the fibrous hollow structure is, in the elastic state, removed from the core in a non-destructive manner, molded into an end contour by application of internal pressure and overmolded with a plastic.

Abstract: A method for producing an object of composite material comprising the steps of: placing one or several prepregs on a plane surface, forming a fiber stack; lifting over the fiber stack to a molding tool; downforming the fiber stack; curing the downformed fiber stack; where the method also comprises the step of: orienting the fiber directions so that all fibers, when the fiber stack is lifted over to the molding tool, will cross an edge of the molding tool only once.

Abstract: According to the invention there is provided an arrangement of protective material for dissipating the kinetic energy of a moving object including one or more layers of fibrous armour material encased within a sealed encasement, in which the sealed encasement is formed from a textile armour material which is impregnated with a polymeric substance.

Abstract: A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a core edge. A first layer of resin preimpregnated tape is wrapped continuously around the first core face, the core edge and the second core face. A thread is stitched along the first layer of preimpregnated tape. A second layer of resin preimpregnated tape wrapped continuously around the first layer of resin preimpregnated tape.

Abstract: A method and apparatus for manufacturing a tool for creating composite components. A sheet metal material is secured over a forming tool in an incremental sheet metal forming machine. The sheet metal material is incrementally shaped with a stylus to form a shape for the tool. The tool is removed from the incremental sheet metal forming machine when the shape for the tool is complete. Composite materials on the tool are laid up, wherein the shape of the tool provides a desired shape for a composite component.

Abstract: Preforms for open structured (lattice) composite tubular members manufactured from large (i.e. high filament count) prepreg yarns on a conventional maypole braiding machine, and subsequently cured to produce fiber reinforced composites of high strength and light weight.

Abstract: A ballistic-resistant moulded article containing a compressed stack of sheets that contain high molecular weight polyethylene tapes. The direction of the polyethylene tapes within the compressed stack is not unidirectional. At least part of the tapes have a width of at least 2 mm, a thickness to width ratio of at least 10:1, and a density of at most 99% of the theoretical tape density. The moulded article is made of tapes that have a density below the theoretical density of the tapes.

Abstract: A reinforcing structure 9 for a wind turbine blade is in the form of an elongate stack 27 of layers 31 of pultruded fibrous composite strips supported within a U-shaped channel 28. The length of each layer 31 is slightly different to create a taper at the ends of the stack; the centre of the stack 27 has five layers 31, and each end has a single layer 31. The ends of each layer 31 are chamfered, and the stack is coated with a thin flexible pultruded fibrous composite strip 33 extending the full length of the stack 27. The reinforcing structure 9 extends along a curved path within the outer shell of the blade. During configuration of the blade components within a mould 37, the reinforcing structure 9 is introduced into the mould 37 by sliding the channel 28 along the surface of an elongate wedge 29 within the mould 37 along the curved path.

Abstract: Materials and methods are provided for producing preform materials for impact-resistant composite materials suitable for liquid molding. Interlayers formed of nonwoven, continuous fibers, such as spunbonded, spunlaced, or mesh fabric, are introduced between non-crimped layers of unidirectional reinforcing fibers to produce a preform for use in liquid-molding processes to produce a composite member. Curing of the preform provides increased impact resistance by increasing the amount of energy required to propagate localized fractures due to impact.

Abstract: A method for manufacturing a fiber composite component having an integral structural design includes positioning a sheet-like fibrous semi-finished product in a mold that defines an outer contour of the fiber composite component. Dimensionally stable fibrous semi-finished products, each having dimensions corresponding to a respective portion of the manufactured fiber composite component, are arranged on the sheet-like fibrous semi-finished product. The dimensionally stable fibrous semi-finished products are stabilized and fixed in place using mold cores. The semi-finished products are resin infiltrated using one of a first or a second gating process so as to form a construct. The first gating process includes gating via the mold cores at a head of each dimensionally stable fibrous semi-finished product and performing extraction in an area of the mold.

Abstract: The present invention provides apparatus and methods for growing fullerene nanotube forests, and forming nanotube films, threads and composite structures therefrom. In some embodiments, an interior-flow substrate includes a porous surface and one or more interior passages that provide reactant gas to an interior portion of a densely packed nanotube forest as it is growing. In some embodiments, a continuous-growth furnace is provided that includes an access port for removing nanotube forests without cooling the furnace substantially. In other embodiments, a nanotube film can be pulled from the nanotube forest without removing the forest from the furnace. A nanotube film loom is described. An apparatus for building layers of nanotube films on a continuous web is described.

Abstract: Plastics articles with continuous reinforcement strands are normally produced by pultrusion. Pultrusion methods are known for producing straight or curved plastics profiles. It has not hitherto been possible for reinforced plastics articles of more complex form to be produced by pultrusion methods. The invention provides a pultrusion method in which a part of a curved plastics article serves, together with a mold (15), for the pultrusion of a reinforced plastics article. In this way, it is possible for complex plastics articles, for example a plastics pipe (10), to be produced by pultrusion.

Abstract: Methods creating composite preforms with a three-dimensional weaving pattern include stacking material layers and then connecting them with interlayer reinforcements. First and second layers are aligned and separated by a first layer spacing. First interlayer reinforcements are then inserted through at least the first and the second layers. At least a third layer is aligned with at least the first and second layers. Second interlayer reinforcements are inserted through at least the second and third layers, using the first layer spacing between the first and second layers to manipulated the second interlayer reinforcements during insertion. Following the insertion of at least the second interlayer reinforcement, this layer spacing is closed to bring the first and second layers into contact. Further layers and interlayer reinforcements may be added, using additional layer spacings to manipulate additional interlayer reinforcements to form complex three-dimensionally woven composite preforms.

Abstract: Embodiments refer generally to systems and methods for manufacturing a cylindrical spar tube of the sort that might be used in a horizontal stabilizer for a helicopter. An exemplary method may comprise laying out onto a flat surface (and possibly stacking) plies of composite material, rolling the material onto a mandrel while applying pressure and curing the rolled material.

Abstract: Protection of elements (1) of composite material protected at its points of complex geometry, such as various edges and corners, against electric discharges to which they are potentially exposed, said elements (1) being obtained by applying a cycle of temperature and pressure to a composite material arranged in a mold (2) designed in such a way that, once the geometry of the element (1) is known, the mold (2) includes free spaces (6) intended for the accumulation of resin from the process of manufacture of said element (1), and said resin will form the dielectric protection of the various edges or corners of the element (1) as it builds up, forming layers (3) that are disposed around the free edges of the element (1), thus endowing these surfaces of various edges or corners with dielectric protection of electrical insulation that prevents possible discharges and expulsion of hot particles in the case of electric discharge on said element (1).

Abstract: A method and apparatus for manufacturing composite components. A tool is present for use in manufacturing composite components. The tool comprises an encapsulation layer having a shape, an insulation layer on the encapsulation layer, and an isolation layer on the insulation layer. The isolation layer has an outer surface capable of contacting a composite material laid up on the outer surface. The insulation layer is capable of insulating the encapsulation layer from heat applied to the composite material. The encapsulation layer is capable of maintaining a shape with the composite material laid up on the isolation layer during a curing process to form a composite component from the composite material.

Abstract: A biodegradable container including a base, at least one sidewall extending from the base and comprising an inner surface and an opposite outer surface, at least a portion of the base and the at least one side wall is formed from seaweed, and a biodegradable polymer coating applied to at least a portion of the base and the at least one sidewall.

Abstract: A method is provided for forming a melt-resistant glass fiber product, by applying an insulating material to a glass fiber product comprised of filiform glass fibers so as to substantially coat each of the filiform glass fibers therewith, such that the coated filiform glass fibers render the glass fiber product resistant to heat. In one aspect, such a method comprises forming a wetted mixture including filiform glass fibers and insulating material comprising a fire-retarding solution, wherein the wetted mixture has a solids content of the fire-retarding solution substantially uniformly and thoroughly dispersed therethrough. An associated apparatus is also provided.

Abstract: Pultrusion methods and apparatus for manufacturing a profiled preform or FRP-component with cross-sectional segments that extend angularly to one another from a plurality of semifinished products in a quasi-continuous process, where: at least one multilayer semifinished product arrangement [of a multilayer semifinished product arrangement] is dispensed from a dispenser unit in order to manufacture the preform, with the multilayer semifinished product arrangement dispensed from the dispenser unit being fed to the forming device and including a combination of several webs of semifinished reinforcement fiber layers and at least one resin film; the semifinished product arrangement is guided through a forming device and at least one cross-sectional segment of the semifinished product arrangement is angled in order to form an angle profile, with the semifinished product arrangement being compressed in a pressing device, optionally after a hardening process, and with a longitudinal section of the preform or the comp

Abstract: A beam of fiber-reinforced curable thermosetting composite material is preliminarily assembled in an uncured condition. The beam is placed between two forming tools, namely a lower and an upper tool, shaped in such a way as to give the lower and upper flanges a predetermined shape, at least one of the flanges having a non-rectilinear profile viewed in a longitudinal vertical plane. Two longitudinally elongate rigid inserts are placed between the flanges at the sides of the web and are covered in respective airtight tubular bags. The spaces between the upper tool and the lower tool on the two opposite longitudinal sides are sealed. The open opposite ends of the tubular bags are also sealed in such a manner that the pressure applied in an autoclave during the step of curing causes the tubular bags to swell and presses them against the two opposite faces of the web and against the flanges of the beam. On completion of curing, the upper forming tool is removed and the inserts are extracted sideways.

Abstract: A patch for a structure has a rework area with an inconsistency formed therein. The patch comprises a patch body having at least two regions including a fail-safe region and a safe-life region encompassing the fail-safe region. The safe-life region has a mode I interlaminar fracture toughness that is less than the mode I interlaminar fracture toughness of the fail-safe region.

Abstract: Methods and apparatus for vacuum infusing resin into a fabric preform within a mold. The methods comprise increasing permeability in a selected region, such as by deploying a VIPR chamber in a location corresponding to the resin injection port corresponding to the resin flow front furthest from the mold vent or a location identified by predictive modeling as best to achieve a desired flow front geometry. Suitable apparatus comprise a VIPR chamber, an image detector for detecting resin flow fronts, a processor programmed to identify a desired location to deploy the VIPR chamber, and an automatic positioner for moving the VIPR chamber to the identified location.

Abstract: The present invention relates to a three dimensionally fiber-reinforced riser and to the unitary or single-step methods of making the same. In one embodiment (a cross bow riser for example), the riser has an interior support with opposed side members and a front brace. The front brace has a depression centrally located therein. Two side ribs are also provided for structural support. Two pockets each optionally having a divider wall defining a top and bottom section are provided for receiving respective top and bottom pieces of a split limb, when a split limb is used. The riser can be made of a composite material having fibers aligned there within in the directions of the highest stresses for enhancing the structural strength of the riser. Other bow parts or components can likewise be made via composite material as well.

Abstract: A mandrel having an out-of-plane curvature and a corresponding in-plane change in mandrel geometry is used to fabricate substantially wrinkle-free, fiber reinforced stiffeners having an out-of-plane curvature.

Abstract: The present invention relates to a method of fabricating a composite part presenting an integral structure of composite material comprising at least one reinforcing layer based on reinforcing fibers, fabrics, or textiles, and at least one impregnation matrix, the method consisting in assembling the integral structure, in placing said integral structure in a mold, in impregnating said integral structure with the impregnation matrix by injection or infusion, and in solidifying said impregnated integral structure by raising it to a determined temperature, the method being characterized in that it consists in: using at least two distinct primary parts for making up the integral structure; placing a thermoplastic sheet on at least one of the primary parts so as to make the interface between said primary parts once they are assembled together.

Abstract: During the cooking of a composite component including layers of fibers embedded into a matrix, a superficial pressure is exerted. This superficial pressure generates a deformation that causes local contacts of fibers of at least two layers without damaging these fibers. As a result, when an electrical current is applied on a side of the composite component, such as during a lightning strike or a short circuit, the added local contacts enable the electric current to flow along multiple fibers in the composite component, thereby avoiding significant spikes in temperature.

Abstract: A method is presented for stably, highly, and efficiently producing a three-dimensional molded article of a fiber-reinforced composite material having a three-dimensional shape, uniform quality, and free from wrinkles by press molding a plurality of prepregs cut out in a predetermined shape and also to a molded article.

Abstract: A method for joining fittings to a composite sandwich shell edge includes laying up an inner facesheet and positioning a wrapped flute mandrel on top; applying a layer of adhesive on the inner facesheet and positioning spacer-supported fittings on top; applying adhesive over the co-bonded fittings and laying up an outer facesheet forming an assembly; curing the assembly under heat and pressure; removing the fittings by first collapsing the spacers and removing the flute mandrel; placing an adhesive layer on the fittings with collapsible spacers inserted therein; reinserting the fittings between the inner and outer facesheets and effecting bonding and curing; and removing the spacers from the fittings by collapsing the spacers.

Abstract: A method of integrally forming a composite rib structure includes positioning a first fiber sheet on a pre-preg mold, the pre-preg mold including a first channel and a second channel separated by a wedge-shaped protrusion, and the fiber sheet including a plurality of fibers oriented along a first common direction. The method further including extending the wedge-shaped protrusion through the first fiber sheet such that a subset of the plurality of fibers are displaced about the protrusion and into each of the respective first channel and second channel; applying a resin within each of respective first channel and second channel to the plurality of fibers; pre-curing the resin to form a pre-preg rib structure within the channels; and removing the pre-preg rib structure from the pre-preg mold.

Abstract: A method of forming a hole in a composite panel includes positioning a first fiber sheet on a layup table, where the layup table has a forming tool extending outward from a portion of the table, and the fiber sheet includes a plurality of fibers oriented along a first common direction. The method further includes extending the forming tool through the first fiber sheet such that a subset of the plurality of fibers are displaced about the forming tool: applying a resin to the sheet of fibers; pre-curing the resin to form a pre-preg part defining a hole about the forming tool; and removing the pre-preg part from the layup table.

Abstract: There is provided a porous, carbon-containing preform, including a body (CL) of unidirectional carbon fiber fabrics (C1), and a friction layer (FL) of randomly-arranged-carbon-fiber fabrics (F1), combined with the body (CL) by a needle-punching operation. According to the present invention, it is by the needle-punching operation that the friction layer (FL) of the randomly-arranged-carbon fiber fabric (F1) is formed on the body (CL) of the unidirectional carbon fiber fabric (C1) and the friction layer (FL) of the randomly-arranged-carbon-fiber (F1) is cross-linked to the body (CL) of the unidirectional carbon fiber fabric (C1) in producing the porous, carbon-containing preform.

Abstract: A pre-form CMC cavity and method of forming pre-form CMC cavity for a ceramic matrix component includes providing a mandrel, applying a base ply to the mandrel, laying-up at least one CMC ply on the base ply, removing the mandrel, and densifying the base ply and the at least one CMC ply. The remaining densified base ply and at least one CMC ply form a ceramic matrix component having a desired geometry and a cavity formed therein. Also provided is a method of forming a CMC component.

Abstract: A method for making parts with variable thickness corners and parts with variable thickness corners are disclosed. The method includes laying up multiple plies to form a tailored blank, associating the blank with a convex and concave die, and applying pressure and heat so that material from at least one of the plies migrates towards a voided corner area formed between the dies.

Abstract: A method of fabricating a reinforced thermoplastic composite part comprises moving a laminate of reinforcing fibers embedded in a thermoplastic matrix for sequential operations through a heating station and then a forming station. The heating station is used to soften the thermoplastic matrix in a portion of the laminate while the forming station is used to impart a geometry to a portion of the laminate whose thermoplastic matrix had just been softened. The softening and the forming are performed simultaneously on different portions of the laminate.