Method for manufacturing a reinforced part, including the steps of: producing a support structure and then covering the support structure, at least partially, with at least one composite material including reinforcement fibres, with local adhesion of the support structure and/or the composite material, during positioning thereof, to ensure its retention on the support structure, the support structure being an integral part of the reinforcing part.

Method for manufacturing a reinforced part, including the steps of: producing a support structure and then covering the support structure, at least partially, with at least one composite material including reinforcement fibres, with local adhesion of the support structure and/or the composite material, during positioning thereof, to ensure its retention on the support structure, the support structure being an integral part of the reinforcing part.

The invention first relates to a method for welding at least two parts comprising a thermoplastic material and having respective surfaces to be welded, comprising: inserting an insert between the surfaces to be welded of the two parts; generating heat via said insert; wherein the insert moves in relation to the parts to be welded in a welding direction. The invention also relates to an installation adapted for implementation of this method.

The invention first relates to a method for welding at least two parts comprising a thermoplastic material and having respective surfaces to be welded, comprising: inserting an insert between the surfaces to be welded of the two parts; generating heat via said insert; wherein the insert moves in relation to the parts to be welded in a welding direction. The invention also relates to an installation adapted for implementation of this method.

Thermoformed molded articles are made containing and from fabrics containing spandex and cellulose ester fibers. In the process for making the molded article, a fabric is layed up in a mold a thermoformed at a temperature not exceeding 195° C., and for a residence time sufficient to obtain a molded article that retains its shape upon release from the mold, said fabric comprising cellulose ester fibers. The three-dimensional molded articles can now be made containing sustainably derived fibers, e.g. cellulose ester fibers, that have good shape retention, comfort, and hand. Examples of such molded articles include support garments, such a brassiers.

Composites containing one or more synthetic plastics, such as thermoplastics, one or more natural materials, such as plant/tree fibers, and biochar and/or torrefied material are described herein. The composite can contain additional additives, such as reinforcing agents and/or fibers, compatibilizers, etc. The composites have improved mechanical and/or physical properties, such as strength, impact strength, rigidity/modulus, heat deflection temperature, moldability/melt flow index, renewability, and lower cost compared to composites that do not contain the biochar and/or torrefied material. The presence of the biochar and/or torrefied material also serves to remove the odor often associated with natural fibers and other additives.

A process for resin transfer molding (RTM) with staggered injection of a resin is provided that injects resin into a plurality of injection ports of a mold. The temperature and pressure applied to the mold are controlled during injection to limit promote rapid filling of the mold cavity. The injection ports are activated for injecting the resin in any order of individually, in groups, or pairings. Fibers are readily added to the mold separately or within the resin. Cycle times of from 1 to 5 minutes are provided for the process.

A thermoformed article is disclosed that includes a self-supporting structural base layer, a covering applied to a first side of the base layer, and one or more secondary features co-injected upon a second side of the base layer. The covering and the secondary features of the thermoformed article are applied to the base layer during the same molding operation. Also disclosed is a process for forming a thermoformed article that includes placing a covering in a mold tool as a first layer, placing a self-supporting structural base layer in the mold tooling as a second layer, closing the mold tooling with the covering and base layer, and co-injecting upon a side of the base layer opposite to the covering one or more secondary features.

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.