An object of the present invention is to provide a prepreg and a laminate for producing a laminate suitable as a structural material, which have excellent compressive strength and interlaminar fractural toughness values, and can be firmly integrated with another structural member by welding. The present invention provides a prepreg including the following structural components [A] reinforcing fibers, [B] a thermosetting resin, and [C] a thermoplastic resin, in which [B] has a rubbery state elastic modulus of 10 MPa or more at a temperature obtained by adding 50° C. to a glass transition temperature in a state in which a degree of cure is 90% or more, [C] is present in a surface of the prepreg, and the reinforcing fibers [A] are present, which are included in a resin area including {B] and a resin area including [C] across an interface between the two resin areas.

An object of the present invention is to provide a prepreg and a laminate for producing a laminate suitable as a structural material, which have excellent compressive strength and interlaminar fractural toughness values, and can be firmly integrated with another structural member by welding. The present invention provides a prepreg including the following structural components [A] reinforcing fibers, [B] a thermosetting resin, and [C] a thermoplastic resin, in which [B] has a rubbery state elastic modulus of 10 MPa or more at a temperature obtained by adding 50° C. to a glass transition temperature in a state in which a degree of cure is 90% or more, [C] is present in a surface of the prepreg, and the reinforcing fibers [A] are present, which are included in a resin area including {B] and a resin area including [C] across an interface between the two resin areas.

A structural arrangement comprising a fiber reinforced polymer component, a cold gas spraying electrically conductive layer, and a polyether sulfone foil arranged on the fiber reinforced polymer component, at least in a region between the fiber reinforced polymer component and the cold gas sprayed electrically conductive layer.

One embodiment is an apparatus including a mold configured to manufacture a composite structure at a heated temperature. The mold includes a first mold tool configured to mold a first portion of the composite structure, wherein the first mold tool comprises a plurality of strands of a fiber-reinforced thermoplastic material, wherein the fiber-reinforced thermoplastic material comprises a thermoplastic embedded with a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is aligned within each strand of the plurality of strands; and an anisotropic thermal expansion property, wherein the anisotropic thermal expansion property is based on an orientation of the plurality of reinforcement fibers within the first mold tool; and a second mold tool configured to mold a second portion of the composite structure.

One embodiment is an apparatus including a mold configured to manufacture a composite structure at a heated temperature. The mold includes a first mold tool configured to mold a first portion of the composite structure, wherein the first mold tool comprises a plurality of strands of a fiber-reinforced thermoplastic material, wherein the fiber-reinforced thermoplastic material comprises a thermoplastic embedded with a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is aligned within each strand of the plurality of strands; and an anisotropic thermal expansion property, wherein the anisotropic thermal expansion property is based on an orientation of the plurality of reinforcement fibers within the first mold tool; and a second mold tool configured to mold a second portion of the composite structure.

A method for manufacturing a composite part by laying up courses of composite tape using an automated tape layup (ATL) machine onto a conductive flexible facesheet laid flat on a flat surface, and then transferring the facesheet with the composite material thereon to a curved tooling surface for attachment of substructures and curing into the composite part. The method may also include applying insulation below the facesheet and above the composite material, then heating the conductive facesheet to cure the composite tape and fuse the composite tape to the substructures without heating the tooling surface or any other items used to compress and cure the composite material into the composite part. Heating of the facesheet may be performed using joule heat provided by a single turn transformer inducing current to a plurality of conductive wires attached at opposing ends to the facesheet.

Systems and methods for printed multifunctional skin are disclosed herein. In one embodiment, a method of manufacturing a smart device includes providing a structure, placing a sensor over an outer surface of the structure, and placing conductive traces over the outer surface of the structure. The conductive traces electrically connect the sensor to electronics.

A method for manufacturing an insulation member for an appliance includes the steps of forming a porous bag with a woven fabric, filling the porous bag with insulation materials, heat sealing the porous bag, vibrating the porous bag to define a pillow, compressing the pillow within a mold to define a compressed insulation member, and evacuating the compressed insulation member within an insulated structure to define a vacuum insulated structure.

A method for manufacturing an insulation member for an appliance includes the steps of forming a porous bag with a woven fabric, filling the porous bag with insulation materials, heat sealing the porous bag, vibrating the porous bag to define a pillow, compressing the pillow within a mold to define a compressed insulation member, and evacuating the compressed insulation member within an insulated structure to define a vacuum insulated structure.

In a metal-fiber reinforced plastic (FRP) composite, the FRP and the metal member are bonded together, so internal stress (thermal stress) is generated due to the misfit of coefficients of thermal expansion of the metal member and the FRP. Not only does the binder layer peel off and the mechanical properties of the FRP cannot be obtained, but also defects in appearance (surface strain) occur. Therefore, the technical problem is to secure the mechanical properties as a composite while easing the internal stress and keeping surface strain from being generated.

The metal-fiber reinforced plastic (FRP) composite according to the present invention solves the technical problem by sandwiching an FRP between two metal members and not having at least one of the metal members joined (bonded) with the FRP. Further, it is possible to arrange an intermediate member between the other metal member and the FRP and sandwich the FRP between the two metal members through the intermediate member.