A process for forming a moldable, uncured nonwoven composite containing forming a structural nonwoven layer, at least partially impregnating the structural nonwoven layer with an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C., and at least partially drying the uncured, wet nonwoven composite such that the temperature at the inner plane is less than about 130° C. forming an moldable, uncured composite. The structural nonwoven layer contains a plurality of bi-component binder fibers and a plurality of reinforcing fibers, the bi-component fibers containing a core and a sheath. The core contains a polymer having a melting temperature of at least about 180° C. and the sheath contains a polymer having a melting temperature less than about 180 ° C. A process for forming a molded, cured composite containing forming a structural nonwoven layer and a molded cured nonwoven composite are also disclosed.

Embodiments of the present technology may include a method of making a thermoplastic composite strand. The method may include melting a reactive thermoplastic resin to form a molten reactive resin. The method may also include fully impregnating a plurality of continuous fibers with the molten reactive resin in an impregnation device. The method may further include polymerizing the molten reactive resin to form a thermoplastic resin matrix. In addition, the method may include cooling the thermoplastic resin matrix to form a thermoplastic composite strand.

Embodiments of the present technology may include a method of making a thermoplastic composite strand. The method may include melting a reactive thermoplastic resin to form a molten reactive resin. The method may also include fully impregnating a plurality of continuous fibers with the molten reactive resin in an impregnation device. The method may further include polymerizing the molten reactive resin to form a thermoplastic resin matrix. In addition, the method may include cooling the thermoplastic resin matrix to form a thermoplastic composite strand.

A process for forming a moldable, uncured nonwoven composite containing forming a structural nonwoven layer, at least partially impregnating the structural nonwoven layer with an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C., and at least partially drying the uncured, wet nonwoven composite. The structural nonwoven layer contains a plurality of binder fibers and a plurality of reinforcing fibers which are cellulosic fibers. Heat and pressure are applied to the moldable, uncured composite to a temperature of at least about 160° C. at least partially melting the binder fibers, curing the water-based thermosetting resin, and bonding at least a portion of the reinforcing fibers to other reinforcing fibers forming the molded, cured composite. The reinforcing fibers react with and form covalent bonds with the thermosetting resin.

A process for forming a moldable, uncured nonwoven composite containing forming a structural nonwoven layer, at least partially impregnating the structural nonwoven layer with an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C., and at least partially drying the uncured, wet nonwoven composite. The structural nonwoven layer contains a plurality of binder fibers and a plurality of reinforcing fibers which are cellulosic fibers. Heat and pressure are applied to the moldable, uncured composite to a temperature of at least about 160° C. at least partially melting the binder fibers, curing the water-based thermosetting resin, and bonding at least a portion of the reinforcing fibers to other reinforcing fibers forming the molded, cured composite. The reinforcing fibers react with and form covalent bonds with the thermosetting resin.

A fiber preform for use in a resin transfer molding or liquid composite molding process and process of making the same are provided. The preform includes a substrate, a fiber bundle arranged on the substrate in a predetermined pattern and attached to the substrate by a plurality of stitches of a thread. The fiber preform is capable of being pre-formed into a three-dimensional shape. The fiber preform along with a sheet of preformed thermoset resin that impregnates at least a portion of the fiber preform forms a composite material. The fiber preform reinforces areas of stress concentration of a core to form a vehicle component.

A fiber preform for use in a resin transfer molding or liquid composite molding process and process of making the same are provided. The preform includes a substrate, a fiber bundle arranged on the substrate in a predetermined pattern and attached to the substrate by a plurality of stitches of a thread. The fiber preform is capable of being pre-formed into a three-dimensional shape. The fiber preform along with a sheet of preformed thermoset resin that impregnates at least a portion of the fiber preform forms a composite material. The fiber preform reinforces areas of stress concentration of a core to form a vehicle component.

A method of manufacturing a radius filler may include providing a plurality of fibers, braiding the plurality of fibers into a braided preform, shaping the braided preform into a braided radius filler, and cutting the braided radius filler to a desired length.

Container comprising an inner container and an outer container with facing surfaces, wherein at least part of at least one of the facing surfaces has a surface roughness higher than about 0.1 Ra and/or wherein the difference in roughness of the facing surfaces is at least over a part more than about 0.1 Ra.

Container comprising an inner container and an outer container with facing surfaces, wherein at least part of at least one of the facing surfaces has a surface roughness higher than about 0.1 Ra and/or wherein the difference in roughness of the facing surfaces is at least over a part more than about 0.1 Ra.