Methods for fabricating high-temperature composite structures (e.g., structures comprising carbon-carbon composite materials or ceramic composite matrix (CMC) materials and configured for use at temperature at or exceeding about 2000 F. (1093 C.)) include forming precursor structures by additive manufacturing (AM) (e.g., 3D printing). The precursor structures are exposed to high temperatures to pyrolyze a precursor matric material of the initial 3D printed structure. A liquid resin is used to impregnate the pyrolyzed structure, to densify the structure into a near-net final shape. Use of expensive and time-consuming molds and post-processing machining may be avoided. Large, unitary, integrally formed parts conducive for use in high-temperature environments may be formed using the methods of the disclosure.

A method of forming a component for a vehicle according to an exemplary aspect of the present disclosure includes, among other things, forming the component of an ultra-high-molecular-weight-polyethylene (UHMWPE) and a stiffening filler. A bracket and a running board assembly are also disclosed.

The present invention provides a structural shell comprising a basalt fibre-reinforced material, wherein the basalt fibre-reinforced material comprises a polymer material, the polymer material being capable of at least partially thermally cracking at a temperature of from 200 to 600 C.

Provided are: a pipe-shaped integrally molded article which is formed by molding a polyphenylene sulfide resin composition, and which has, at one or more portions thereof, at least one selected from different-shape sections, bent sections, and different-diameter sections, the pipe-shaped integrally molded article being characterized in that the total length L (mm) thereof is 1000 or more, and the ratio (L/D) of the total length L (mm) to the outer diameter D (mm) of the pipe-shaped integrally molded article is 20 or more: and a production method for the pipe-shaped integrally molded article. According to the present invention, it is possible to efficiently provide a pipe-shaped integrally molded article having a desired large length and including a three-dimensionally complicated shape, by using a PPS resin composition having excellent heat resistance and chemical resistance.

Methods for fabricating high-temperature composite structures (e.g., structures comprising carbon-carbon composite materials or ceramic composite matrix (CMC) materials and configured for use at temperature at or exceeding about 2000 F. (1093 C.)) include forming precursor structures by additive manufacturing (AM) (e.g., 3D printing) with a filament drawn from a spool. The precursor structures are exposed to high temperatures to pyrolyze a precursor matric material of the initial 3D printed structure. A liquid resin is used to impregnate the pyrolyzed structure, to densify the structure into a near-net final shape. Use of expensive and time-consuming molds and post-processing machining may be avoided. Large, unitary, integrally formed parts conducive for use in high-temperature environments may be formed using the methods of the disclosure.

The present invention is directed to fiber composite structures, including one or more composite fibers or igneous rock fibers, such as basalt fibers and/or andesite fibers, that are impregnated with a polymer resin and subsequently coated with a frictional additive, such as aluminum oxide. The frictional additive provides for improved frictional engagement when the fiber composite structures are included in concrete or other structural materials and reduces alkaline degradation of the composite structures within the concrete over time. A process for manufacturing the fiber composite structures is also described herein. The process includes inductive heating of the fiber composite structures in order to cure the polymer resin, so as to affectively apply heat without being impeding by the external layer of frictional additive.

A composite floor comprises a coextrusion layer compression molded using a coextrusion process. The layer comprises a first stone-plastic layer, a stone-plastic foaming layer, and a second stone-plastic layer sequentially arranged from top to bottom. The stone-plastic foaming layer is used as the main material layer, which reduces a whole weight of the floor; and the first stone-plastic layer and the second stone-plastic layer are arranged at two sides of the stone-plastic foaming layer, respectively, so that the composite floor is more stable. It is more environmentally friendly and simple in manufacturing to use the coextrusion process for compression molding by avoiding bonding using glue. Use of the coextrusion process makes various layers bond more compact, with little delamination and warpage due to effect of environmental changes. The composite floor has a low expansion rate and shrinkage rate, excellent in performance and long in service life.

A composite member comprises first and second elongate composite elements. Each has a wedge shaped end with a complimentary tapered end surface. At least one of the components is formed of a stack of fiber layers impregnated in resin, with the tapered end surface being formed by each fiber layer extending longitudinally progressively further than the adjacent layer towards the thin end of the wedge at which the fiber layers have the greatest longitudinal extent. The components are joined at their tapered ends by an adhesive, and the properties of the cured composite material of the at least one component and/or the properties of the adhesive are different in the vicinity of the thin end of the wedge as compared to the rest of the tapered surface in order to reduce the stress concentrations in this region.

A composite member comprises first and second elongate composite elements. Each has a wedge shaped end with a complimentary tapered end surface. At least one of the components is formed of a stack of fiber layers impregnated in resin, with the tapered end surface being formed by each fiber layer extending longitudinally progressively further than the adjacent layer towards the thin end of the wedge at which the fiber layers have the greatest longitudinal extent. The components are joined at their tapered ends by an adhesive, and the properties of the cured composite material of the at least one component and/or the properties of the adhesive are different in the vicinity of the thin end of the wedge as compared to the rest of the tapered surface in order to reduce the stress concentrations in this region.

The present invention provides a continuous method for producing a fiber-reinforced semi-finished plate. The present invention also provides a device for carrying out the continuous method for producing a fiber-reinforced semi-finished plate. The present invention provides the fiber-reinforced semi-finished plate.