A thermoplastic composite structure is produced by consolidating and forming a composite preform to a desired shape. The preform comprises plies of a high melt temperature thermoplastic prepreg that are tacked together by a low melt temperature thermoplastic adhering the plies together in fixed registration.

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 method for consolidating a thermoplastic component includes positioning a thermoplastic vacuum bagging film (e.g., PAEK or PEEK) over a thermoplastic preform (e.g., PPS or LM PAEK) to be consolidated, vacuum consolidating the thermoplastic component with the thermoplastic vacuum bagging film to form the thermoplastic component, and removing the thermoplastic vacuum bagging film from the consolidated thermoplastic component.

Embodiments herein include extruded articles, building components and methods of making the same. In an embodiment, an extruded article is included. The extruded article can include a body member including a first portion comprising a first composition, the first composition comprising a polymer resin. The extruded body member can also include a second portion comprising a second composition different than the first composition. The second composition can include a polymer resin, fibers, and at least one component selected from the group consisting of at least 1% by weight particles and at least 5 phr impact modifier. Other embodiments are also included herein.

A method to produce a panel. The method includes providing a core having a first surface, providing a surface layer including a substantially uncured amino resin, applying an hydrolysable adhesive on the first surface of the core and/or on a surface of the surface layer adapted to face the core, arranging the surface layer on the first surface of the core, pressing the surface layer to the core to form a panel by applying heat and pressure in a press, thereby adhering the surface layer to the core by the hydrolysable adhesive and curing the amino resin of the surface layer. Also such a panel.

The present disclosure relates to a method for providing a film. The method may include providing a base layer, wherein the base layer is resistant to one or more of water or oxygen; coextruding a tie layer and a contact layer to provide a coextrusion layer; coating the coextrusion layer to the base layer; allowing the coextrusion layer coated to the base layer to adhere to form the film, wherein the film comprises the tie layer and the contact layer formed as a coextrusion layer coated to the base layer; wherein the tie layer comprises one or more layers, and wherein the tie layer, or the one or more layers of the tie layer, has a loading in the range of 7 to 20 g/m.sup.2; wherein the contact layer comprises a cycloolefin copolymer (COC).

Thermoplastic bags include laminates with bonded protrusions. More specifically, one or more implementations include a first thermoplastic film with a plurality of raised rib-like elements extending in a direction perpendicular to a main surface of the first thermoplastic film and second thermoplastic film bonded to the protrusions (e.g., raised rib-like elements or troughs between the raised rib-like elements) of the first thermoplastic film. By bonding a second thermoplastic film to the protrusions of the first thermoplastic film, the resulting laminate has an increased effective gauge or loft. In one or more implementations the second thermoplastic film is a flat film. In alternative implementations, the second thermoplastic film comprises a plurality of raised rib-like elements extending in a direction perpendicular to a main surface of the second thermoplastic film and protrusions of the first thermoplastic film are bonded to protrusions of the second thermoplastic film.

An intermediate material of a thermoplastic prepreg for a fuel cell separation plate comprises a hydrophobic thermoplastic resin film and a fiber base. The hydrophobic thermoplastic resin film has a degree of crystallization of 1 to 20%, a thickness of 3 to 50 μm, and (iii) a content of an electroconductive material of 1 to 20 wt. %. The film is laminated on at least one surface of the fiber base. The thermoplastic prepreg for a fuel cell separation plate is manufactured by pressurizing the thermoplastic prepreg intermediate material at a temperature higher than the melting point of the hydrophobic thermoplastic resin film. A fuel cell separation membrane manufactured using the thermoplastic prepreg intermediate material and thermoplastic prepreg is thin and light-weight, and have a good durability.

A method for bonding components is provided. The method includes preparing a surface of a metal component, applying a film adhesive to the prepared surface, forming a thermoplastic component using injection molding such that the film adhesive is positioned between the metal component and the thermoplastic component, and curing the film adhesive.

The invention relates to a structured body and a method for its preparation, whereby the structured body is produced of at least one powdery starting material by application of heat and/or pressure, and has several layers, whereby the starting material consists predominantly of thermoplastic basic material, and whereby the density of at least two layers of the structured body differ from each other, and whereby at least one layer of lower density contains hollow microspheres.