Abstract: An object is to provide a composite material manufacturing method for improving interlayer strength. The present disclosure provides a composite material manufacturing method of laminating a plurality of prepregs (10) formed of a fiber reinforced base material impregnated with an uncured matrix resin and performing hot molding, the method including: using the prepregs (10) each provided with a gap layer (12) that does not contain a resin and is continuous in an in-plane direction and resin layers (11a, 11b) disposed on both surfaces of the gap layer; disposing a plurality of short fibers (13) on facing surfaces of the prepregs (10) that are adjacent to each other; and evacuating the laminated prepregs (10) to degas the gap layer (12) and then performing hot molding.

Abstract: There is provided a random mat including carbon fibers and a matrix resin, wherein the carbon fibers in the random mat have an average fiber length in a range of 3 mm to 100 mm, a fiber areal weight of the carbon fibers is 25 to 10,000 g/m2, the carbon fibers include a specific carbon fiber bundles having a specific opening degree in a specific amount per the total carbon fibers, and the specific carbon fiber bundles with a thickness of 100 ?m or more are included in a ratio of less than 3% of the number of the total specific carbon fiber bundles.

Abstract: Systems and methods are provided for fabricating composite parts that include both chopped fiber and continuous fiber components. One embodiment is a method that includes laying up a laminate comprising at least one ply of continuous fiber-reinforced polymer onto a first surface of a mold, filling a cavity of the mold with chopped fibers and resin that contact the laminate, curing the chopped fibers and the laminate together into an integral composite part, and separating the integral composite part from the mold.

Abstract: Provided is a laminated substrate wherein a sheet-shaped material with a porosity of 50-99% is laminated onto at least one surface of a prepreg substrate which includes a reinforcing fiber and a thermoplastic resin.

Abstract: A beam sub-assembly for a vehicle includes a beam member and at least one carbon-fiber prepreg bonded to a first portion of an exterior surface of the beam member so as to cover an entire length of the beam member along the first portion.

Abstract: Provided a vehicle skeleton member including: a portion obtained by joining a plurality of members constituted by a composite material of a thermoplastic resin and a reinforcing fiber, and an axis parallel to a front-rear direction and/or a right-left direction of the vehicle body is included in a joined surface by vibration welding.

Abstract: A composite golf club head with improved sound characteristics is disclosed herein. More specifically, the present invention relates to a golf club head that utilizes a unique composite type material having a low damping coefficient; creating more discretionary weight to optimize performance without comprising the sound of the golf club head. Depending on the amount of discretionary weight desired, the present invention could replace parts of the crown, the sole, the striking face, or even all three of the above referenced components with a low-damping composite material to improve the performance. The low-damping composite material used in accordance with the current invention may generally have a damping loss factor (?) of less than about 0.02.

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: Described herein is a meltspun laminate comprising two or more layers of meltspun fabrics, wherein layers that are adjacent to one another are in situ entangled with one another to define an interfacial region of mixed fibers between the layers. Also described herein is a method of making a meltspun in situ laminate comprising simultaneously meltspinning two or more polymer melts adjacent to one another to form adjacent fabrics, wherein layers that are adjacent to one another are in situ entangled with one another to form an interfacial region of mixed fibers between the layers. Also described herein is a meltspinning apparatus comprising one or more dies, each die comprising two or more meltspinning zones, wherein each zone comprises a plurality of nozzles that are fluidly connected to the corresponding zone, and wherein each zone is fluidly connected to a melt extruder.

Abstract: Building board for use as a carrier for a surface cladding of ceramic tiles, a stucco, or a thin-layer trowel mortar, on or in buildings, in which on a moisture-resistant and moisture-sealed foam-material core layer, there is glued on both sides a water-resistant paper web or thin plastic web, onto which webs in each case a web of nonwoven fabric or of a knitted or loom-knitted woven fabric is glued.

Abstract: A resin-soluble thermoplastic polymer veil toughening element for a curable composition wherein the polymer element is a non-woven veil in solid phase adapted to undergo at least partial phase transition to fluid phase on contact with a component of the curable resin matrix composition in which it is soluble at a temperature which is less than the temperature for substantial onset of gelling and/or curing of the curable composition and which temperature is less than the polymer elements melt temperature; a method for the preparation thereof, a preform support structure for a curable composition comprising the at least one thermoplastic veil element together with structural reinforcement fibers, methods for preparation thereof, a curable composition comprising the at least one thermoplastic veil element or the support structure and a curable resin matrix composition, a method for preparation and curing thereof, and a cured composite or resin body obtained thereby, and known and novel uses thereof.

Abstract: Thermoplastically deformable composite materials have a core layer with a glass fiber woven ply connected on both sides thereof to a fiber nonwoven ply of polypropylene fibers and glass fibers. The core layer is connected with at least one cover layer which comprises polypropylene fibers and polyethylene terephthalate fibers. The composite materials are produced by needling the individual layers and heating to melt the polypropylene fibers. The composite materials are useful for preparing automotive parts.

Abstract: An acoustic composite containing at least a first acoustically coupled non-woven composite and a second acoustically coupled non-woven composite, each acoustically coupled non-woven composite containing a non-woven layer and a facing layer. The non-woven layer contains a plurality of binder fibers and a plurality of bulking fibers and has a binder zone and a bulking zone. The facing layer of the second acoustically coupled non-woven composite is adjacent the second surface of the non-woven layer of the first acoustically coupled non-woven composite.

Abstract: A composite having a first layer and a second layer. The first layer is a nonwoven layer containing high modulus fibers having a modulus of at least 8 GPa and thermoplastic binder fibers, where at least a portion of the high modulus fibers are connected to the binder fibers, and where the first layer has a solidity of between about 10 and 90%. The second layer is a textile layer selected from the group consisting of a knit layer, a woven layer, bidirectional laminates, and a unidirectional layer. The second layer contains high modulus fibers having a modulus of at least 8 GPa in a thermoplastic matrix.

Abstract: An allergen trap is provided. The allergen trap includes a woven or nonwoven substrate having at least one strata. The trap is impregnated with or otherwise treated with a tacky adhesive by which allergens may be trapped. An example of an allergen is a dust mite. The tacky adhesive, in turn, may be treated with a miticide or activated carbon.

Abstract: A paper transporting felt includes a base layer, a first batt layer formed on a wet paper side surface of the base layer, a second batt layer formed on a press side surface of the base layer, a polymer elastic material impregnated in the base layer, the first batt layer and the second batt layer, and a wet paper contacting layer which is formed on a wet paper side surface of the first batt layer so as to come into direct contact with a wet paper, and includes a flexible resin material. The compressibility of the wet paper contacting layer is larger than that of a layer formed of the base layer, the first batt layer and the second batt layer.

Abstract: A paper transporting felt includes a base layer, a first batt layer formed on a wet paper side surface of the base layer, a second batt layer formed on a roll side surface or a shoe side surface of the base layer, and a wet paper contacting fibrous layer formed on a wet paper side surface of the first batt layer so as to come into direct contact with a wet paper. The wet paper contacting fibrous layer is made of modified cross-section fibers.

Abstract: A paper transporting felt includes a base layer, a first batt layer formed on a wet paper side surface of the base layer, a second batt layer formed on a roll side surface or a shoe side surface of the base layer, and a wet paper contacting layer formed on a wet paper side surface of the first batt layer so as to come into direct contact with a wet paper. The wet paper contacting layer is formed of a flexible resin material.

Abstract: The present invention relates generally to composite materials and to methods of manufacturing the composite materials. In particular, the composite material of the present invention utilizes combinations of continuous fibers in the form of loops, chopped fibers, woven fibers and foams.

Abstract: Dense, highly stable, high performance ballistic material comprises at least one woven layer of ballistic grade fiber (preferably a stack of such layers) and at least one nonwoven layer of fabric which is entangled with the woven or unidirectional layer by needle felting. The resulting core material does not require assembly of individual woven layers during subsequent manufacture of ballistic articles and exhibits excellent ballistic performance at low areal densities and thicknesses.

Abstract: The asphalt waterproofing sheet and a joint sealing structure thereof can improve the fire resisting capacity of an asphalt waterproofing layer by the laminating of an aluminum film and a polymer layer on an asphalt sheet thereby to prevent the overheat of a roof structure by reflecting the incident sunlight. Here, the asphalt sheet may allow a release paper to be attached to the bottom surface thereof.

Abstract: A buffing or polishing material has a nonwoven fleece layer and a backing layer that adds strength and dimensional stability to the material. The nonwoven fleece layer is a needled blend of natural fibers and synthetic fibers having a uniform density and working surface, resulting in a better polishing or finishing consistency. The material can withstand high heat levels and can be worked quickly, resulting in a more efficient polishing or finishing operation. The buff material can be converted into any preferred shape or tool, such as an endless belt, disc, flapwheel, or spiral band.

Abstract: A polished-piece holder is provided that does not easily stick or adsorb to a polishing pad of a polishing apparatus and reduces occurrences of production line troubles and therefore the number of failed polished pieces. A single sheet of a thermosetting resin impregnated fiber substrate or a laminated sheet formed by laminating a plurality of sheets of the thermosetting resin impregnated fiber substrate is formed under heat and pressure into a plate. The thermosetting resin impregnated fiber plate is then processed to form a polished-piece holder for holding pieces to be polished. The evaluation portion has a certain length in a direction of the average line. The thermosetting resin impregnated fiber plate has a surface roughness with a maximum wave height Ry of 10 &mgr;m or greater over an almost entire area of the surface layer.

Abstract: A polished-piece holder capable of preventing a polished piece from taking scratches, being increased in wear resistance, thickness accuracy, warpage resistance and dimensional stability, and preventing a deterioration in polishing accuracy. The polished-piece holder includes a core layer and a wear-resistant surface layer laminated on at least one of front and rear surfaces of the core layer. The core layer is constituted of at least one thermosetting resin impregnated fibrous layer and the surface layer is likewise constituted of a thermosetting resin impregnated fibrous layer. The thermosetting resin impregnated fibrous layer constituting the surface layer is subject to heating and pressurizing, to thereby provide a prepreg wherein a nonwoven aramid fiber substrate is impregnated with thermosetting resin.

Abstract: A cushioning material for forming press includes fiber material layers 31 and 32 superimposed with a bonding material layer 30 interposed, an upper rubber layer 33 positioned on an upper surface of one fiber material layer 31, a lower rubber layer 34 positioned on a lower surface of the other fiber material layer 32, an upper exudation preventing layer 35 positioned on an upper surface of the upper rubber layer 33, and a lower exudation preventing layer 36 positioned on a lower surface of the lower rubber layer 34.

Abstract: Plies of continuous fiber material are oriented and cut to the intended shape of a structural component, such as the vertical tail of an aircraft. Two skins or laminates are created by laying the cut-to-shape plies into a matched mold, with over-woven or over-braided mandrels or similar tooling details placed between the skins. The mold is closed and a thermosetting resin is injected into the mold to fully impregnate any fibers that were unimpregnated at the time of mold closure and to fully fill all void areas inside the mold. The mold is held closed with pressure, such as by a press, and heated to cure the resin while the resin in the mold is subjected to a hydrostatic pressure sufficient to constrain growth of voids. The contiguous faces of the impregnated braid or weave covering the mandrels are united by the resin, forming vertical or angular laminate between the inner faces of the skins.

Abstract: This invention concerns a non-woven composite, comprising a fabric or knitted fabric and at least one layer of a non-woven fabric, in which the fabric or the knitted fabric and the non-woven layer(s) are bonded with each other. This invention also describes a process for the production of this non-woven composite as well as its use as a stiffening lining, in particular a patch lining, for example for the strengthening and padding of sleeves in the shoulder bone zone, for strengthening in the waist band zone or of hats and/or caps.

Abstract: A laminated board comprising an intermediate layer and two surface layers formed thereon, in which board the intermediate layer comprises a central layer made of a nonwoven glass fiber fabric impregnated with a resin composition containing a thermosetting resin and an inorganic filler and upper and lower layers formed on the central layer, each being made of said resin composition containing a thermosetting resin and an inorganic filler, and the two surface layers formed on the intermediate layer are made of a thermosetting resin-impregnated fiber substrate; and a process for production of the laminated board.