The present invention relates to a composition comprising a fibrous material, a multistage polymer and a (meth)acrylic polymer. The composition can be in form of a prepreg, a preform or a laminate. The present invention further relates to a method for making a composition comprising a fibrous material, a multistage polymer and a (meth)acrylic polymer and its use in making composite articles. The present invention also relates to a process for preparing a composition comprising a fibrous material, a multistage polymer and a (meth)acrylic polymer and its use for producing fibre reinforced impact modified composites.

In a method for producing a fiber-reinforced composite material, the fiber-reinforced composite material is formed by impregnating a reinforcing fiber sheet with a resin and curing the resin. The method includes: storing the reinforcing fiber sheet in a cavity of a forming mold; and impregnating the reinforcing fiber sheet with the resin by injecting the resin into the cavity of the forming mold, and curing the resin. In the impregnating and curing, the resin containing a magnetic powder is injected into the cavity, and a magnetic field is generated in the cavity to cause the resin containing the magnetic powder to flow.

Systems and methods are provided for fabrication of short-fiber composites. One embodiment is a method for forming a short-fiber composite. The method includes forming a bed of randomly oriented dry fibers on a base, drawing resin into the bed in response to pressure to form a mixture of randomly oriented fibers impregnated with thermoset resin, perturbing the mixture while preserving fiber length at the mixture and degassing the mixture, and extruding the mixture to form a preform.

Systems and methods are provided for fabrication of short-fiber composites. One embodiment is a method for forming a short-fiber composite. The method includes forming a bed of randomly oriented dry fibers on a base, drawing resin into the bed in response to pressure to form a mixture of randomly oriented fibers impregnated with thermoset resin, perturbing the mixture while preserving fiber length at the mixture and degassing the mixture, and extruding the mixture to form a preform.

According to a manufacturing method and device for manufacturing a composite material having reinforced base materials with a resin impregnated in the reinforced base materials. An unactivated powdered adhesive is applied to at least one surface of a plurality of carbon fiber sheets. The carbon fiber sheets are laminated to form a laminate. At least a portion of the unactivated powdered adhesive that is applied between layers of the laminate is removed using an airflow that flows from one exterior surface of the laminate to an opposite exterior surface of the laminate to form a preform having a first region in which the activated adhesive is impregnated in the laminate, and a second region in which a content density of the activated adhesive is less than that in the first region.

Methods of making prepregs are described. The methods include the steps of forming a fiber-containing substrate, and contacting the fiber-containing substrate with a resin mixture. The resin mixture may include polymer particles mixed in a liquid medium, and the polymer particles may be coated on the fiber-containing substrate to form a coated substrate. The liquid medium may be removed from the coated substrate to form the prepreg. The prepregs may be used to make fiber-reinforced articles.

Methods of making prepregs are described. The methods include the steps of forming a fiber-containing substrate, and contacting the fiber-containing substrate with a resin mixture. The resin mixture may include polymer particles mixed in a liquid medium, and the polymer particles may be coated on the fiber-containing substrate to form a coated substrate. The liquid medium may be removed from the coated substrate to form the prepreg. The prepregs may be used to make fiber-reinforced articles.

A method is provided for the preparation of a semifinished product made of fiber material with an upper side and with an underside prior to a wet-pressing process. The method includes following steps: arrangement of a semifinished product made of fiber material with the underside on a preparation area with a large number of suction apertures, application of a reduced pressure to the underside of the semifinished product by way of the suction apertures, and introduction of a flowable matrix material by way of the upper side of the semifinished product.

A method is provided for the preparation of a semifinished product made of fiber material with an upper side and with an underside prior to a wet-pressing process. The method includes following steps: arrangement of a semifinished product made of fiber material with the underside on a preparation area with a large number of suction apertures, application of a reduced pressure to the underside of the semifinished product by way of the suction apertures, and introduction of a flowable matrix material by way of the upper side of the semifinished product.

The invention enhances the production efficiency in the production of prepreg by allowing the arrangement property and rectilinearity of reinforcing fibers to be well maintained, allowing the basis weight uniformity of an applied resin to be good, and further allowing a high line speed and suppression of contamination in the process to be achieved. The invention provides a method of producing a prepreg, which includes: discharging a molten resin from a discharge portion; introducing the discharged resin by an air flow; and capturing the discharged resin on a reinforcing fiber sheet conveyed continuously, wherein a key point is that the discharged resin is captured in a region in which the reinforcing fiber sheet is conveyed substantially in planar form.