A method of bonding a thermoplastic component to a carpeted component and the carpeted component to cellulose-based core in a single pressing step is provided. The method includes providing a base component of a reinforced thermoplastic material, the thermoplastic component, a fibrous thermoplastic carpet or mat between the components, a sheet of thermoplastic adhesive and a core of cellulose-based material. The method also includes heating the thermoplastic component and the carpet at the interface between the thermoplastic component and the carpet for a period of time to soften the carpet. The method finally includes pressing the components, the sheet, the core and the softened carpet together under a pressure to cause the softened carpet to flow. The carpet at the interface is transformed into a solid bonding layer to bond the components together and the sheet bonds the base component and the core together to create a finished structure.

An aramid fabric having excellent adhesion to a polyurethane matrix resin and excellent tensile strength is produced by the method including the steps of: (i) weaving a basket-structured aramid fabric by using aramid yarns as warp and weft yarns; and then (ii) dipping the woven aramid fabric in a sizing agent solution consisting of an aqueous polyurethane resin as a sizing agent and water, followed by squeezing and drying. In the present disclosure, the sizing agent is applied to the woven aramid fabric, thereby effectively preventing the deterioration in weaving efficiency. Further, the aramid fabric is woven in a basket weave, and thus the compactness of the aramid fabric is lowered and the wetting property of the aramid fabric with the polyurethane matrix resin is improved.

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 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 system (100), for manufacturing a rotor blade (112), comprises a first tooling (170), positioned at a factory location (114) and configured to assemble a first blade module (116), comprising a first-module skin (118) and a first-module spar (120), each comprising a first thermoplastic polymer (122) and a first reinforcement material (124). The system (100) comprises a second tooling (172), configured to assemble a second blade module (126), comprising a second-module skin (128) and a second-module spar (130), each comprising a second thermoplastic polymer (132) and a second reinforcement material (134). The system (100) comprises a first support (160), positioned at a field location (140) and configured to receive the first blade module (116), and a second support (162), positioned at the field location (140) and configured to receive the second blade module (126). The system (100) comprises a spar welding assembly (174), positioned at the field location (140) and configured to join the first-module spar (120) with the second-module spar (130), and a skin welding assembly (176), positioned at the field location (140) and configured to join the first-module skin (118) with the second-module skin (128).

A system (100), for manufacturing a rotor blade (112), comprises a first tooling (170), positioned at a factory location (114) and configured to assemble a first blade module (116), comprising a first-module skin (118) and a first-module spar (120), each comprising a first thermoplastic polymer (122) and a first reinforcement material (124). The system (100) comprises a second tooling (172), configured to assemble a second blade module (126), comprising a second-module skin (128) and a second-module spar (130), each comprising a second thermoplastic polymer (132) and a second reinforcement material (134). The system (100) comprises a first support (160), positioned at a field location (140) and configured to receive the first blade module (116), and a second support (162), positioned at the field location (140) and configured to receive the second blade module (126). The system (100) comprises a spar welding assembly (174), positioned at the field location (140) and configured to join the first-module spar (120) with the second-module spar (130), and a skin welding assembly (176), positioned at the field location (140) and configured to join the first-module skin (118) with the second-module skin (128).

A tank (e.g., an underground storage tank), and manufacturing methods therefore, may include a tank body having an exterior surface. A component is mounted on at least a non-planar portion of the exterior surface of the tank body using an adhesive (e.g., an MMA adhesive). For example, the component may be positioned on the non-planar portion of the exterior surface of the tank body after application of adhesive and pressure may be applied to maintain the position of the component on the non-planar portion of the exterior surface of the tank body as the adhesive is cured. The pressure may be removed upon curing of the adhesive and formation of a structural bond may occur at the adhesive interface between the mounting surface of the component and the non-planar portion of the exterior surface of the tank body.

A tank (e.g., an underground storage tank), and manufacturing methods therefore, may include a tank body having an exterior surface. A component is mounted on at least a non-planar portion of the exterior surface of the tank body using an adhesive (e.g., an MMA adhesive). For example, the component may be positioned on the non-planar portion of the exterior surface of the tank body after application of adhesive and pressure may be applied to maintain the position of the component on the non-planar portion of the exterior surface of the tank body as the adhesive is cured. The pressure may be removed upon curing of the adhesive and formation of a structural bond may occur at the adhesive interface between the mounting surface of the component and the non-planar portion of the exterior surface of the tank body.

A structure, comprising a multilayer fabric infused by a resin, is disclosed. There is also provided a method for manufacturing a structure, comprising, laying a multilayer fabric over a mold of the structure; and infusing a resin into the multilayer fabric. The structure can be, by way of example only, a canoe, a wind fairing, a panel for use as wall decoration, a cover of a body of a vehicle, a corn hole game surface or a pickle ball paddle face.

A flexible elastomeric grip for the shaft of a golf club having an end cap with a cavity for receiving a sensor and/or counterweight. The cap has a durometer hardness equal to or greater than the tubular body portion of the grip and a flange sized to match the larger diameter of the body, with a sleeve engaging the inner periphery of the larger end of the tubular body. In one version of the cap, the sleeve portion is extended in length and has stiffening ribs on the outer surface of the sleeve; and, in another version, the sleeve is shorter and may also have stiffening ribs on the outer surface of the sleeve. In another version of the cap, fibrous material is disposed in the flange and sleeve to increase lateral stiffness without increasing durometer.