A method of manufacturing curved composite structural elements can include fabricating a web ply in a flat curve over a removable substrate and laying up the ply on a curved web surface of a manufacturing tool. The method also can include laying up a diagonal ply with fibers oriented at +/45 from the centerline of the web surface. The method further can include cutting a unidirectional composite tape into segments and laying up the tape segments to form a cross ply with a fiber orientation normal to the centerline of the web surface. One or both edges of the diagonal and cross plies may be folded over one or two sides of the manufacturing tool to form one or two flange surfaces. Additionally, a cap ply can be laid up on one or both flange surfaces using composite tape. The structural element layup can then be inspected and any excess composite material can be trimmed away.

A method for manufacturing rigid panels made of a composite material requires a caul sheet having a smooth surface that is formed with a plurality of grooves. A first layer of the composite material is laid on the caul sheet, and is cut to create flaps that extend into the respective grooves. Strips of composite material are then placed along the edges of the groove to extend and overlap each other in the groove. Next, a unidirectional ply is placed along the length of the groove, and this combination is then covered with a second layer of the composite material. Together, the combination of the first and second layers, the strips and the unidirectional ply are co-cured to create a rigid panel with integral stiffening members.

A composite laminate comprises a plurality of plies of reinforcing fibers. At least some of the plies have reinforcing fibers oriented at with respect to an axis of primary loading, where is between 2 and 12 degrees. At least some of the plies have reinforcing fibers oriented at with respect to the axis of primary loading, where is between 50 and 85 degrees.

Provided is a rubber laminated resin composite comprising a polyamide-based resin molded product and rubber that is vulcanization bonded to the polyamide-based resin molded product; the polyamide-based resin molded product being molded from a polyamide-based resin that is blended with 0 to 70 wt. % of a filler based on the total amount of the filler and the polyamide-based resin, and that comprises an aliphatic amine compound having an amine equivalent of 950 or less in an amount of 0.045 mmol or more, preferably 0.050 to 2.0 mmol, more preferably 0.065 to 1.5 mmol, per g of the polyamide-based resin. The rubber laminated resin composite is produced by molding a polyamide-based resin that is blended or not blended with a filler, after the addition of an aliphatic amine compound thereto, and then vulcanization bonding of fluororubber or acrylic rubber to the obtained polyamide-based resin molded product.

Provided is a rubber laminated resin composite comprising a polyamide-based resin molded product and rubber that is vulcanization bonded to the polyamide-based resin molded product; the polyamide-based resin molded product being molded from a polyamide-based resin that is blended with 0 to 70 wt. % of a filler based on the total amount of the filler and the polyamide-based resin, and that comprises an aliphatic amine compound having an amine equivalent of 950 or less in an amount of 0.045 mmol or more, preferably 0.050 to 2.0 mmol, more preferably 0.065 to 1.5 mmol, per g of the polyamide-based resin. The rubber laminated resin composite is produced by molding a polyamide-based resin that is blended or not blended with a filler, after the addition of an aliphatic amine compound thereto, and then vulcanization bonding of fluororubber or acrylic rubber to the obtained polyamide-based resin molded product.

There is provided a technique to strongly integrate a galvanized steel sheet and a resin molded article. A hot-dip galvanized steel sheet is immersed in an aqueous solution for aluminum degreasing to form a specific roughness on the surface. The surface is covered with convex protrusions having a diameter of about 100 nm, and a chromate treatment layer appears in the surface. A resin composition comprising 70 to 97 wt % of polyphenylene sulfide and 3 to 30 wt % of a polyolefin resin is injected onto the surface. The resin composition penetrates into ultra-fine irregularities and is cured in that state, and thereby a composite in which the galvanized steel sheet and the resin molded article are strongly integrated can be obtained. The shear rupture strength of the composite is extremely high.

In a method for processing a fibre compound structure, an unhardened fibre layer is arranged on a surface section of the fibre compound structure. A pressure cushion is arranged above the surface section. The pressure cushion has a pressure cap and a pressure-tight cap mat pressure-tightly connected to a circumferential border of the pressure cap such that the cap mat limits a pressure area together with the pressure cap. An overpressure in the pressure area is generated. The pressure cushion is pressed onto the fibre compound structure such that the overpressure presses the cap mat against the fibre layer while supporting the fibre compound structure on a side of the fibre compound structure that is opposed to the surface section. The fibre layer is hardened

An isotropic fiber-reinforced thermoplastic resin sheet wherein a chopped strand prepreg comprising a thermoplastic resin and a reinforcing fiber is layered so that the fiber orientation is random, the prepreg having a fiber volume fraction (Vf) of 20% to 50%, a length in the fiber axis direction of 15 to 45 mm, and a thickness of no greater than 0.13 mm, and the layered material is molded into sheet form by heating and pressing, and a molded plate obtained from the isotropic fiber-reinforced thermoplastic resin sheet. Even if the volume fraction of the reinforcing fiber is relatively low, a fiber-reinforced thermoplastic resin sheet and a molded plate that are excellent in terms of mechanical properties and their uniformity can be obtained.