The present invention relates to a molding made from foam, wherein at least one fiber (F) is partly within the molding, i.e. is surrounded by the foam. The two ends of the respective fibers (F) that are not surrounded by the foam thus each project from one side of the corresponding molding. The foam comprises at least two mutually bonded foam segments.

A thermoplastic product includes a fabric-based reinforcing sheet and a polymerized thermoplastic material. The fabric-based reinforcing sheet is wound about a mandrel to form a plurality of layers having a cross-sectional shape that corresponds to the mandrel. The fabric-based reinforcing sheet includes a plurality of fiber bundles, which may have a bidirectional orientation or configuration. A polymerized thermoplastic material is disposed within each layer of the fabric-based reinforcing sheet. The polymerized thermoplastic material bonds each layer of the fabric-based reinforcing sheet to an adjacent layer.

A method for manufacturing a turbine nozzle vane made of ceramic matrix composite material, wherein the vane is manufactured using a first fibrous preform including a hollow central section intended to form a fibrous reinforcement of an airfoil of the vane to be obtained, and a pair of second fibrous preforms each having an opening with a shape of the airfoil of the vane to be obtained.

Disclosed herein is a method of reinforcing a composite comprising determining a location of a first cooling hole in a plurality of plies; where a cooling gas is transported through the cooling hole; disposing a z-fiber in the plurality of plies at a location proximate to where the first cooling hole will be located; where the z-fiber enters the plurality of plies at either an upper surface or a lower surface; and where the z-fiber traverses a portion of the plurality of plies in the z-direction proximate to the first cooling hole; and traverses the plurality of plies in an x or y direction further away from the first cooling hole; where the z-direction is in the thickness direction of the plurality of plies and where the x and y-direction are perpendicular to the z-direction.

Structurally enhanced preformed layers of multiple rigid unidirectional rods are constructed and arranged for use in fabricating load-bearing support structures and reinforcements in a variety of composite components, e.g. wind turbine blades. Individual preform layers include multiple elongate unidirectional strength elements or rods arranged in a single layer along a longitudinal axis of the preform layer. Individual rods include aligned unidirectional structural fibers embedded within a matrix resin such that the rods have a substantially uniform distribution of fibers and high degree of fiber collimation. The relative straightness of the fibers and fiber collimation provide rods and the preform layers with high rigidity and significant compression strength. A plurality of rods are loosely attached, e.g. knitted, together with a coupling that allows for each rod to be axially displaced, e.g. slideable, relative to another rod.

A method of fabricating a laminar composite article, includes steps of spreading a plurality of continuous fiber tows from a spool to form a first ply layer having a substantially consistent layer thickness, applying a binder to the spread plurality of continuous fiber tows, curing the plurality of continuous fiber tows and applied binder at a cure temperature less than a thermal decomposition temperature of the binder, and processing the cured plurality of continuous fiber tows at a post-cure temperature greater than the cure temperature.

Embodiments are directed to systems and methods for two or more cured composite assemblies that are bonded together to form a tubular composite structure, wherein each of the cured composite assemblies do not have a tubular shape. The tubular composite structure may form a spar for an aerodynamic component, for example. The two or more cured composite assemblies may comprise carbon or fiberglass composite materials or a combination of materials. Each of the cured composite assemblies may further comprise axial edges that are configured to be bonded to another of the cured composite assemblies, wherein the axial edges have a sloped shape. An adhesive agent may be applied on the axial edges for bonding two cured composite assemblies. Alternatively, or additionally, one or more fasteners may be used to attach the axial edges of at least two cured composite assemblies.

Low-density thermoplastic expandable microspheres are disclosed. Various low-density structures, in particular, sandwich panels, based on foam prepared from the low-density microspheres, are also disclosed. Process of preparing low-density polymeric microspheres, per se, and the corresponding low-density structures, based on the microsphere foam, are also disclosed.

A prepreg containing a carbon fiber [A] and a thermosetting resin [B], and in addition, satisfying at least one of the following (1) and (2). (1) a thermoplastic resin particle or fiber [C] and a conductive particle or fiber [D] are contained, and weight ratio expressed by [compounding amount of [C] (parts by weight)]/[compounding amount of [D] (parts by weight)] is 1 to 1000. (2) a conductive particle or fiber of which thermoplastic resin nucleus or core is coated with a conductive substance [E] is contained.

The present invention generally relates to a system and method for using a volatile organic compound (VOC) free low radiant flux LED UV curable composition, and more particularly to unique and novel uses of the composition such as one or two or more of a fire retardant, clear coat, composite material, resin, top coat, improved holdout coating, a sealant coat, and combinations of the same.