Abstract: A method for preparing an uncured supported elastomer material includes the steps of: providing a fibrous reinforcement material; providing a layer of uncured elastomer material substantially adjacent to the fibrous reinforcement material; exposing the layer and the fibrous reinforcement to a temperature below a curing temperature and above a flow point of the uncured elastomer material, and a pressure sufficient that the uncured elastomer material flows into the fibrous reinforcement material, so as to provide an uncured supported elastomer material.

Abstract: There is disclosed a prepreg including noncircular cross-section carbon fibers and a matrix resin having a flexural elastic modulus of 2.7 GPa or more and a water absorption of 3.4% or less under hot-wet conditions after curing; and another prepreg including carbon fibers and a matrix resin having an open-hole compression strength under hot-wet conditions and a compression strength after impact under room-temperature conditions of a quasi-isotropic material after curing of each 275 MPa or more. Carbon fiber-reinforced composite materials produced by curing these prepregs are excellent in open-hole compression strength under hot-wet conditions and in compression strength after impact, and can be suitably used especially as an aircraft primary structure material.

Abstract: An elastomeric composite structure 45 having two arrays of parallel cords 41, 43, each array of cords 41,43 being of different modulus or percent elongation. The array of cords 41,43 are spaced and provide different bending stiffness dependent on the direction of the applied load.

Abstract: This invention relates to carbon--carbon (C--C) composite comprising carbon fibers or carbon fabric, carbon char on the carbon fiber or fabric and pyrolytic carbon on the carbon char, wherein the density of the carbon composite is at least 1.3 g/cc. The invention also relates to wet friction elements and power transmission devises containing the same. The invention also relates to methods of preparing the carbon--carbon (C--C) composites. These C--C composites and wet friction elements and power transmission devises made therefrom have improved friction properties desired by wet brakes and clutches. These C--C composites provide improvements in cost, and when run against metals, such as steel or iron, improvements in wear and frictional behavior compared to known C--C composites for wet friction applications. In one aspect, the carbon--carbon does not require bonding to a metal backing or core material.

Abstract: An axially extending tubular composite member having a plurality of plies and extending along a longitudinal axis has at least three plies with selectively structured fiber components in each ply. Typically an inner ply has at least one biaxial fiber component, an intermediate ply has at least an axial fiber component that typically is combined with two further fibers to form a triaxial fiber component. Another ply typically has a woven fiber component. A further ply having a biaxial component either replaces the ply of woven fiber or is disposed beneath it over the intermediate ply. A surface veil having fiber and an excess of resin material typically covers at least the innermost or outermost surface of the composite member. An internal web member can be provided, and typically also employs fibers and the matrix material.

Abstract: A first air bag comprises an upper cloth and a lower cloth, the peripheries of the both cloths being connected, characterized in that the upper cloth consists of an airtight sheet obtained by weaving a composite fiber composed of a filament core and a thermoplastic polymer bonded thereto-which has a melting point lower than that of said filament core, and then fusing said thermoplastic polymer so that the surface of said upper cloth has a continuous thermoplastic polymer layer. A second air bag consists of a membranous material having a breaking extension of 100% or more. A third air bag comprises an elastomer body and a shape-retaining member partially attached to the elastomer body, said member being composed of elastic fibers or threads and high-modulus fibers.

Abstract: A sacrificial fabric structure is disclosed for protection from the moving chain in chain saws. The structure includes fabric woven in a loose satin weave.

Abstract: A method and resultant article are provided which optimize the adhesion of resin to the glass fibers in fiberglass cloth impregnated with a resin and also optimize the adhesion of the impregnated resin to metal sheets laminated to the resin-impregnated cloth. The fiberglass is treated in two or more passes. On the first pass, the fiberglass is impregnated with a first resin which is optimized for adherence to glass fibers and the coated resin is partially cured. In a last pass, the fiberglass is impregnated with a second resin, which is different from said first resin, and is optimized for bonding to metal. The second resin is then partially cured. The first and second resins are selected such that they form a bond with each other when cured.

Abstract: Woven or laid structures comprising at least two systems of parallel threads, at least one of these thread systems having more than 10 threads per centimeter and comprising at least 10%, based on the thread system, of hybrid yarns comprising reinforcing filaments and lower melting matrix filaments composed of thermoplastic polymers. In such woven or laid structures, the matrix component can be melted to form textile sheet materials of adjustable gas and/or liquid permeability, which are especially useful for manufacturing airbags.

Abstract: The present invention is related to a composite microporous polyolefin membrane having a high separation, a high flux and a high strength, comprising a microporous layer, b-layer, providing a reinforcing function, the b-layer being stacked on at least one surface of a microporous layer, a-layer, providing a separate function, wherein micropores in a-layer and b-layer are mutually interconnected inside of the layer and also between layers, thereby forming micropores connected from one surface of the membrane to the other surface thereof, and the ratio of the mean distance Da between microfibril bundles of micropores existing in a-layer to the mean distance Db between microfibril bundles of micropores existing in b-layer is in the range of 1.3.ltoreq.Db/Da.ltoreq.15, and furthermore all of the inner and the outer surfaces of the composite membrane and the surface inside of micropores are coated by a thin film of a hydrophilic copolymer.

Abstract: The invention relates to the field of forming fibrous structures. A fibrous structure according to the invention has an upper group of fibrous layers and lower group of fibrous layers subjacent the upper group of fibrous layers. A multitude of Z-fiber bundles cohere the fibrous layers, each fibrous layer within the upper group of fibrous layers having a portion of the multitude of Z-fiber bundles originating in that fibrous layer and passing through a number of fibrous layers disposed beneath that fibrous layer without passing through all of the fibrous layers disposed beneath that fibrous layer. The number of fibrous layers penetrated by the Z-fiber bundles is constant within the first portion.

Abstract: The invention's first embodiment uses shape memory alloy (SMA) fibers that are blended into a concrete composite material as straight fibers and are made to deform themselves and anchor and interlock themselves after dispersement in the composite material resulting in a more evenly distributed and interlocked fiber reinforcement of the cementitious material. A self-shaping fiber can be imparted to the concrete material by making the fibers out of SMA such as nickel-titanium alloy known as nitinol where the cementitious composite material mixture is briefly heated above the "transition" temperature prior to hardening that causes the fibers to change shape. Nitinol fibers are used alone in place of conventional steel fibers.

Abstract: Described is a composite comprising at least one textile sheet construction composed of synthetic polymer and hybrid yarn comprising reinforcing fiber and lower melting bonding fiber. Also described is a net comprising in at least one direction hybrid yarns composed of reinforcing fiber and of lower melting bonding fiber. The composites can be used for producing bituminized roofing and sealing membranes.

Abstract: The present invention provides a lightweight prepreg having uniform formation, low linear thermal expansion coefficient and good mechanical strength, comprising a porous para-oriented aromatic polyamide film and a thermoplastic resin and/or a thermosetting resin, the porous para-oriented aromatic polyamide film being impregnated with the thermoplastic resin and/or the thermosetting resin, a process for producing the same, and a printed circuit substrate/board using the same.

Abstract: There is disclosed an electrical component having an axial direction and two ends for making electrical contact with another component comprising a plurality of electrically conductive fibers in a matrix, the plurality of the fibers being oriented in the matrix in a direction substantially parallel in the axial direction of the component and being continuous from one end of the component to the other end to provide a plurality of electrical point contacts at each end of the component, wherein the component further includes magnetic particles.

Abstract: The invention provides composites of ultra-high molecular weight polyethylene reinforced with ultra-high molecular weight polyethylene anisotropic reinforcement of high strength and modulus. The composites have superior mechanical properties relative to non-filled ultra-high molecular weight polyethylene, including higher strength, impact strength, increased creep resistance, and improved modulus. The composites may be sterilized for biomedical use, using gamma radiation and other techniques. Further, the composites are resistant to the effect of body fluids and have lower creep rates so that they will provide implant life. The composites may be cross-linked by exposure to an acetylene environment. Also, the composites find use in other high strength, high impact applications such as sports equipment.

Abstract: The invention provides composites of ultra-high molecular weight polyethylene reinforced with ultra-high molecular weight polyethylene anisotropic reinforcement of high strength and modulus. The composites have superior mechanical properties relative to non-filled ultra-high molecular weight polyethylene, including higher strength, impact strength, increased creep resistance, and improved modulus. The composites may be sterilized for biomedical use, using gamma radiation and other techniques. Further, the composites are resistant to the effect of body fluids and have lower creep rates so that they will provide implant life. The composites may be cross-linked by exposure to an acetylene environment. Also, the composites find use in other high strength, high impact applications such as sports equipment.

Abstract: The present invention provides a protective material comprising a base layer comprising cut resistant yarn, an intermediate layer comprising natural fiber and an outer layer comprising a flexible, elastomeric material impervious to liquid. The intermediate layer is bonded to the elastomeric material, while the cut resistant yarn in the base layer remains substantially free of encapsulation by the elastomeric material. The intermediate layer is joined to said base layer at one or more locations, preferably by selective strike through of limited amounts of the elastomeric material to encapsulate yarn in the base layer.

Abstract: A nonwoven fabric of chemically bonded non-cellulose fibers having improved wet tensile properties. The fabric includes a random arrangement of non-cellulose fibers and an essentially formaldehyde free latex binder. The latex binder contains at least about 6.7 wt % vinyl cyanide monomer to bond the non-cellulose fibers and form a nonwoven fabric having at least a 10% improvement in wet tensile strength over a comparable nonwoven fabric having a latex binder essentially free of formaldehyde and free of vinyl cyanide monomer in the monomeric mixture.

Abstract: A method for manufacturing bands of bituminized roofing material, wherein a band of porous carrier material is impregnated with bitumen, wherein the band of porous carrier material is provided on a supporting surface provided with openings, hot bitumen is provided on the side of the band of carrier material remote from the supporting surface, and a pressure difference is created across the supporting surface, so that the hot bitumen penetrates into the carrier material.

Abstract: A computer model calculates a critical aspect ratio for a discontinuous fiber composite having fibers dispersed in a matrix. The critical aspect ratio is a function of the elastic modulus and the cohesive energy of the fiber and the matrix. The composite incorporates physical features such as fiber shape features or additives in the fiber or matrix which adjust the elastic modulus and/or cohesive energy of the fiber, of the matrix or both to a value different than the corresponding value for unmodified fiber material or matrix material. These adjustments are selected so that the critical aspect ratio for the material including the modifications will be less than the corresponding critical aspect ratio for the material without the modifications. The resulting composite provides enhanced load sharing between fiber and matrix.

Abstract: A description is provided of laminates for printed circuits using unidirectional glass fabric produced with continuous yarn which is twisted, has a low number of twists or zero twisting turns with different gramme weights, interlaced warpwise with a leno interwoven binding using glass yarns of 5.5 to 22 Tex at a spacing of up to 20 cm. The application of these laminates to the manufacture of printed circuits offers advantages in terms of surface roughness and waviness, dimensional stability, evenness and perforability.

Abstract: A product is provided in a continuous length formed from a fiber-reinforced resin and having a shape ratio ?whole length of the contour of the section (Lmm)/real area of the section (Smm.sup.2)! of 0.5 to 2.5/mm and a thickness of 1 to 4 mm. This product in a continuous length is prominently excellent in tensile strength, though the amount of the fiber reinforcement contained in the product is almost the same as in conventional fiber-reinforced products. Hence, the product in a continuous length is favorably used as a spacer for concrete form.

Abstract: A woven glass fabric reinforcement for paper or resinous articles made of continuous glass filament warp yarns and weft yarns is provided. At least one of the warp yarns and the weft yarns is a zero-twist yarn made of continuous glass filaments having a diameter of between about 5 and 13 microns and a yarn count of between about 5.5 and 136 Tex.

Abstract: The present invention relates to mat-shaped composites having porosities above 60% and densities below 0.6 g/cm.sup.3, comprising an aerogel and fibers dispersed therein, the aerogel having cracks and the aerogel fragments enclosed by the cracks, whose average volume is 0.001 mm.sup.3 to 1 cm.sup.3, being held together by the fibers. The present invention further relates to processes for producing the composites of the invention and to their use.

Abstract: Tough laminated composite material which comprise (A) long reinforcing fibers, (B) a matrix resin mixed with the long reinforcing fibers and (C1) a resin, preferably in the form of fine resin particles, forming a phase separate from said matrix resin which is localized in inter-layer zones, wherein 90% or more of said resin (C1) is localized in inter-layer zones and/or wherein the border length factor in the inter-layer zones is 2.5 or more and prepregs used to form the composite materials.

Abstract: The present invention relates to processes for enhancing the bond strength of a cement matrix including reinforcement fibers and for modifying the surface characteristics of reinforcement fibers useful in cementitious materials. The processes further relate to controlling the interface properties and, more particularly, the bond strength (.tau.) and interface toughness (T.sub.i), between synthetic fibers and a cementitious material forming a matrix. By plasma treating synthetic fibers with an excitable gas capable of displacing hydrogen atoms occurring along said reinforcement fibers, the bond strength and interface toughness of the composite is dramatically increased over composites employing non-plasma treated fibers.

Abstract: The invention provides fabrics having improved ballistic performance and processes for making the same. The fabrics include a network of consolidated multifilament yarns formed of high strength filaments. At least a portion of the high strength filaments of the yarns are temporarily locked together to provide a substantially stable, flattened cross-sectional configuration to the yarns. The resultant fabrics are capable of absorbing an impact from a projectile, i.e., a bullet or shrapnel, directed toward the fabric and substantially decreasing its velocity. The fabric can also provide slippage or movement of the yarns relative to one another to dissipate the energy of impact of a projectile across a greater surface area of the fabric.

Abstract: A composite web structure utilizing a thin first layer of material having a plurality of structural fibers arranged to lie essentially in a unidirectional orientation. A thin second layer of material is positioned adjacent the first layer and includes a plurality of structural fibers. First and second layers are impregnated with a matrix material for binding fibers within the first and second layers and for binding the first and second layers together. The web may be formed into a composite structure such as a honeycomb core for fabrication into a panel.

Abstract: A three-dimensional woven fabric structure is integrally woven by a multi-ply weave having three or more plies, and includes a form defining a plurality of bag portions extending parallel with one another, and arranged in a plurality of rows. The bag portions in each row are defined by two woven fabric plies, the intersection of which along a crossing locus creates a bound portion between adjacent bag portions. Cylindrical bag portions in adjacent rows have a woven fabric ply in common and are interconnected at staggered positions. The fabric structure is creased at midpoints between bound portions whereby the bag portions are set to retain a hollow three-dimensional form, but may be folded flat into a juxtaposed state by application of pressure.

Abstract: This invention provides a reinforcing woven fabric using as weaving threads flat and substantially nontwisted multifilaments of reinforcing fiber having less than 0.5 wt. % of sizing agent provided thereto and a binding property of 400-800 mm in hook drop value, and a method and an apparatus for manufacturing a reinforcing woven fabric by weaving the multifilaments of reinforcing fiber as warps and wefts. A reinforcing woven fabric having a small thickness and an extremely high covering factor and capable of indicating a high strength can be obtained at a low cost as a substrate for reinforcing composite materials.

Abstract: A fiber preform having a web and at least one flange has fibers disposed in the web such that each follows a zig-zag path and is interlocked with the fibers of the flange. A manufacturing method for the preform includes interlocking the web yarns with those of the flange and engaging the web yarns at a plurality of points spaced longitudinally of the prefrom and also spaced from the flange in the direction of the web to define the required web dimension.

Abstract: The present invention provides a load-bearing structure having interlockable peripheral edges. The peripheral edges provide at least one pair of upper and lower offsets. Each offset includes a plurality of spaced apart projections.

Abstract: A rubber-polyester composite comprising a rubber and a core-and-sheath heterocomponent fiber wherein the fiber core is formed from a linear polyester derived from an alkyl glycol and an aromatic diacid, and wherein the fiber sheath is formed from a compatibilizing acid-terminated or isocyanate-terminated polyester. The fiber sheath may also be composed of a blend of a thermoplastic elastomer and the compatibilizing polyester.

Abstract: An entangled multifilament yarn made from high strength filaments having a tenacity of at least about 7 g/d, a tensile modulus of at least about 150 g/d and an energy-to-break of at least about 8 J/g. The yarn is used to make ballistic resistant articles.

Abstract: A patient support fashioned of a core of carbon-fiber material and a synthetic material for binding the carbon-fiber material. The carbon-fiber core has a greater proportion of carbon fibers oriented substantially in lengthwise directions than in other directions. As a result of this construction, the patient support is substantially inflexible along its longitudinal axis yet flexible along its lateral axis. The sides of the support can be drawn up and around the patient, to hold the patient immobile within the support, which is especially helpful when transporting trauma patients and those with back and neck injuries. The support is also transparent to radiation, making it particularly suited to use with radiation imaging devices. Finally, the exterior surface of the support is formed of low-friction material, further facilitating practical use thereof. The support can be fashioned as a backboard or a patient transfer device and has a wide range of advantageous applications in a hospital environment.

Abstract: Concrete structures, such as beams, columns, decks, walls, and the like are reinforced by advanced fibrous composite, concrete reinforcing devices, embedded in concrete, the devices comprising, respectively, at least one continuous band of tow, yarn, or strand of high strength, high modulus, fibrous laminate material having a multitude of very fine structural filaments as laminae bonded together in endless belt formation, such band or bands forming a bar of endless belt formation having at least two length portions extending longitudinally in substantially coextensive spaced relationship as load-bearing tendons, with end portions continuing around opposite ends of the device in unbroken continuity. The tendons of the bar may be either straight or deflected and may be pre-tensioned or post-tensioned. A band may be interlaced as a continuous perimeter, mesh shell.

Abstract: The invention relates to a composite web comprising one elongated flat composite layer of mutually parallel fibers in a matrix, in which the fibers run at an angle .alpha. (differing from 0.degree.) relative to the lengthwise direction of the web, and which in the lengthwise direction is made up of joined-up and connected web parts. This composite web can be used for continuously producing multi-layer composites. The composite layer of the composite web has no areas with overlap or gaps when placed in a multi-layer composite. The invention also relates to a method for the production of this composite web and of multi-layer composites.

Abstract: An insensitive composite pressure vessel for containing an energetic compound includes at least two fibers having different temperature resistance characteristics. A dynamic fiber loses a substantial portion of its tensile strength at a transformation temperature which is preferably substantially less than the combustion temperature of the energetic compound, whereas a stable fiber retains substantially all of its tensile strength at temperatures exceeding the transformation temperature. Hence, a pressure vessel formed of dynamic fibers and stable fibers has sufficient burst strength to resist operating pressures under normal conditions. The vessel loses strength and develops additional orifices to vent combustion products from the energetic compound in the event of an external fire, thereby allowing unintentionally ignited rocket motors to burn substantially in place.

Abstract: Dimensionally stable (shrink-resistant) polyester fibers, webs and fabrics, comprising a nucleating agent incorporated into the fibers are disclosed. Methods of incorporating the nucleating agent within the polyester are disclosed.

Abstract: A hot soft nip calender apparatus is provided for a paper mill. The apparatus includes at least one heated calender roller and a finishing belt which is moved in proximity to the heated calender roller by a plurality of drive rollers and at least one pressure roller. Thus, a heated calender nip is defined between the heated calender roller and the finishing belt. A web of paper is passed through the nip, such that one surface of the web of paper is contacted by the heated calender roller, while the opposed surface of the web is contacted by the finishing belt. The finishing belt has an extremely smooth surface for contacting the web of paper so as to impart appropriate smoothness and gloss characteristics to that surface. The finishing belt can readily be changed when worn or damaged or to alter the characteristics being imparted to a web of paper.

Abstract: A synthetic reinforcement having surface features that facilitate adhesion of the reinforcement to another surface and a process for making the same is disclosed. The synthetic reinforcement is comprised of a plurality of continuous fibers that are maintained in position by a resin encasement. An external surface of the synthetic reinforcement can be characterized by micro-recesses that are located in a generally random pattern, which increases the surface area of the resin encasement.

Abstract: The graphitized composite article of the present invention is formed by embedding carbon fiber felt in a matrix of a carbon filler; a thermosetting resin and a solvent; curing the composite article; then, carbonizing and graphitizing the cured composite article to form the graphitized composite article for use as a separator plate capable of substantially inhibiting mixing of hydrogen and oxygen and/or the loss of electrolyte within a fuel cell stack. The graphitized composite article may be a graphitized laminate.

Abstract: The present invention provides a prepreg obtained by stretching a material including, as a main component, an ultra-high-molecular-weight polyethylene having an intrinsic viscosity of 5-50 dl/g as measured at 135.degree. C. in decalin, to a total draw ratio of at least 20, subjecting the resulting stretched polyethylene material to a splitting treatment, and impregnating the resulting material with a thermosetting resin. The split stretched polyethylene material has improved adhesion to the impregnant resin and can be used as a good base material for prepreg.

Abstract: An improved process to make composites contains the steps of: (1) partially curing a tackifier resin in contact with a substrate to form a shapeable preform; (2) adding a matrix resin and co-curing the tackifier and matrix resin to form a composite. The resulting composites are useful in structural applications.

Abstract: A triaxial fabric composed of carbon fiber strands is provided, which has a crimp releasing ratio (L'-L)/L satisfying ?(L.sub.0 -L)/L.sub.0 !.times.0.7.gtoreq.(L'-L)/L.gtoreq.0. Since the crimps of the fiber strands composing the fabric are preliminarily fixed, fiber breakage due to abrasion in the intersecting portions of the fabric is prevented, whereby a high quality triaxial fabric is obtained. A method for the production of such a fabric is also provided.

Abstract: Light filler material consists of a bonded, woven or knitted, short- or long-fibered material web into which thermoplastic hollow microglobes are embedded. This voluminized fiber web is compressed by means of a sewing or stitch-bonding process with the aid of pre-tensioned sewing threads. In the process, the hollow spaces between the voluminized microglobes are reduced in an exactly calculable form by the adjustable thread tension.

Abstract: An article made from at least one network of high strength fibers and a thermoplastic polyurethane matrix material derived from an aliphatic didiisocyanate and a polyol. Preferably, the article is made from at least one prepreg element which includes at least two adjacent layers of the high strength fiber network in the thermoplastic polyurethane matrix material.

Abstract: The laminate is formed of a sheet of a woven textile material derived from multifilamentary aramid, polyimide, polyamide, polybenzimidazole or cellulose fire retardant yarns and a sheet of non-woven textile material. The adhesive used to produce the laminate should prevent slippage of the two materials relative to one another and fraying of the woven textile material while enabling the laminate to be air permeable, and having a minimum ten (10) cubic feet per minute (CFM) when tested in accordance with test method ASTM D737. This product is cheaper to manufacture and is more comfortable than the known quilted and coated material.

Abstract: Ultra-oriented, crystalline synthetic filaments with high tenacity are produced by extrusion of a fiber-forming synthetic polymer melt into a liquid isothermal bath maintained at a temperature of at least 30.degree. C. above the glass transition temperature of the polymer, withdrawing the filaments from the bath and then winding up the filaments. Polymer filaments so produced are characterized in that the ratio of the crystalline orientation factor (f.sub.c) to the amorphous orientation factor (f.sub.a) is 1.2 or less, and are further characterized in that the percent crystallinity is less than 40. The filaments also have a fine crystal size. The crystal size is less than 40 .ANG. in the 100 and 105 planes and less than 30 .ANG. in the 010 plane.