A method may produce a heat-resistant resin composite excellent in heat resistance and bending properties. This heat-resistant resin composite is constituted of a matrix resin and reinforcing fibers dispersed in the matrix resin. The matrix resin is constituted of a heat-resistant thermoplastic polymer having a glass transition temperature of 100° C. or higher, and a polyester-based polymer comprising a terephthalic acid unit (A) and an isophthalic acid unit (B) at a copolymerization proportion (molar ratio) of (A)/(B)=100/0 to 40/60. The proportion of the heat-resistant thermoplastic polymer in the composite is 30 to 80 wt %.

A method may produce a heat-resistant resin composite excellent in heat resistance and bending properties. This heat-resistant resin composite is constituted of a matrix resin and reinforcing fibers dispersed in the matrix resin. The matrix resin is constituted of a heat-resistant thermoplastic polymer having a glass transition temperature of 100° C. or higher, and a polyester-based polymer comprising a terephthalic acid unit (A) and an isophthalic acid unit (B) at a copolymerization proportion (molar ratio) of (A)/(B)=100/0 to 40/60. The proportion of the heat-resistant thermoplastic polymer in the composite is 30 to 80 wt %.

The disclosed materials, methods, and apparatus, provide novel ultra-high temperature materials (UHTM) in fibrous forms/structures; such “fibrous materials” can take various forms, such as individual filaments, short-shaped fiber, tows, ropes, wools, textiles, lattices, nano/microstructures, mesostructured materials, and sponge-like materials. At least four important classes of UHTM materials are disclosed in this invention: (1) carbon, doped-carbon and carbon alloy materials, (2) materials within the boron-carbon-nitride-X system, (3) materials within the silicon-carbon-nitride-X system, and (4) highly-refractory materials within the tantalum-hafnium-carbon-nitride-X and tantalum-hafnium-carbon-boron-nitride-X system. All of these material classes offer compounds/mixtures that melt or sublime at temperatures above 1800° C.—and in some cases are among the highest melting point materials known (exceeding 3000° C.). In many embodiments, the synthesis/fabrication is from gaseous, solid, semi-solid, liquid, critical, and supercritical precursor mixtures using one or more low molar mass precursor(s), in combination with one or more high molar mass precursor(s). Methods for controlling the growth, composition, and structures of UHTM materials through control of the thermal diffusion region are disclosed.

A circular needle loom comprises a bed plate for receiving a transport layer. Engagement members may be disposed proximate to the bed plate, such that the engagement members interface with a positional structure of the transport layer that is used to position and rotate the transport layer around the bed plate. The engagement members may be configured to rotate the transport layer around the bed plate until a predetermined number of fibers and/or layers are deposited on the transport layer and/or bed plate in order to create a needled preform.

A circular needle loom comprises a bed plate for receiving a transport layer. Engagement members may be disposed proximate to the bed plate, such that the engagement members interface with a positional structure of the transport layer that is used to position and rotate the transport layer around the bed plate. The engagement members may be configured to rotate the transport layer around the bed plate until a predetermined number of fibers and/or layers are deposited on the transport layer and/or bed plate in order to create a needled preform.

Systems and methods for forming a fibrous preform are disclosed. The method may comprise providing a plurality of needles comprising a barbed needle and a barbless needle and penetrating the fibrous preform with the plurality of needles.

A nonwoven fabric and a method of making thereof. The nonwoven fabric includes a plurality of randomly-oriented fibers, the plurality of randomly-oriented fibers including: at least 60 wt % of oxidized polyacrylonitrile fibers; and from to less than 40 wt % of reinforcing fibers having an outer surface comprised of a (co)polymer with a melting temperature of from 100° C. to 450° C.; and a fluoropolymer binder on the plurality of randomly-oriented fibers; wherein the plurality of randomly-oriented fibers is bonded together to form the nonwoven fabric, optionally wherein the nonwoven fabric has a thickness of one millimeter or less.

A method for horizontally splitting rolled-up web material in the sample thickness. A carbon fiber nonwoven is moved in relation to a knife structure in order to split off a layer or successively several layers from a roll web. The one layer or several layers are continuously removed in the form of a roll from the carbon fiber nonwoven after the splitting process.

A method for horizontally splitting rolled-up web material in the sample thickness. A carbon fiber nonwoven is moved in relation to a knife structure in order to split off a layer or successively several layers from a roll web. The one layer or several layers are continuously removed in the form of a roll from the carbon fiber nonwoven after the splitting process.

A support (100) for handling pre-formed woven fabric layers to be used for conical shell composite components or segments is described. The support comprises a shaped portion (120) having a plurality of peaks (170) and a plurality of troughs (180) extending between first and second longitudinal edges (130, 140). Each peak has a varying amplitude along its extent and is configured to maintain warp and weft fibres of the pre-formed woven fabric layers perpendicular to one another. A clamping member may be used to retain a stack of pre-formed woven fabric layers in place on the support. The support may also be used for forming non-woven fibre layers and stacks formed from such non-woven fibre layers, and, for the subsequent handling thereof.