Techniques for inlaying a composite material within a tooling shell are disclosed. In one aspect, an additively manufactured tooling shell is provided, into which a composite material is inlaid and cured. A surface of the tooling shell is provided with indentations or another mechanism to enable adherence between the composite material and the tooling shell. The resulting integrated structure is used as a component in a transport structure.

An object of the present invention is to reduce or eliminate a defect (e.g., a void) by achieving (i) a semipreg and a prepreg each of which allows a reduction in residual volatile component and (ii) methods for producing the semipreg and the prepreg, respectively, and consequently to achieve (iii) a fiber-reinforced composite material which has high heat resistance and superior mechanical strength and a (iv) a method for producing the fiber-reinforced composite material. The present invention attains the above object by providing, for example, a semipreg containing: powders of an imide oligomer; and reinforcement fibers, the imide oligomer being represented by a specific general formula (1).

An apparatus and method for laminating fibers for direct manufacturing of a preform, in which rows of fibers are drawn at the same time and are arranged in the form of a preform. The apparatus for laminating fibers for direct manufacturing of a preform according to an aspect of the present invention is an apparatus which supplies reinforced fibers to a table 22 and laminating the reinforced fibers thereon, so as to manufacture a fiber preform by laminating the reinforced fibers on the table 22, the apparatus including: a reinforced fiber supply robot 30 configured to supply a predetermined length of a plurality of reinforced fibers, on which a thermoplastic resin is coated; at least one or more edge fixing robots 40 configured to press and fix an end of the reinforced fibers drawn from the reinforced fiber supply robot 30 to the table 22 while the reinforced fibers are adhered as the thermoplastic resin is melted. Particularly, the reinforced fiber supply robot 30 includes: a plurality of reels 33, around which the reinforced fibers F coated with the thermoplastic resin are wound; a plurality of supply rollers 34 configured to transfer the reinforced fibers F, drawn from the plurality of reels, to the table 22 to supply the reinforced fibers thereto; a cutter configured to cut the reinforced fibers F, supplied through the plurality of supply rollers 34, into a predetermined length; and a compression roller 37 configured to press the end of the reinforced fibers F, cut by the cutter, to the table 22.

An apparatus and method for laminating fibers for direct manufacturing of a preform, in which rows of fibers are drawn at the same time and are arranged in the form of a preform. The apparatus for laminating fibers for direct manufacturing of a preform according to an aspect of the present invention is an apparatus which supplies reinforced fibers to a table 22 and laminating the reinforced fibers thereon, so as to manufacture a fiber preform by laminating the reinforced fibers on the table 22, the apparatus including: a reinforced fiber supply robot 30 configured to supply a predetermined length of a plurality of reinforced fibers, on which a thermoplastic resin is coated; at least one or more edge fixing robots 40 configured to press and fix an end of the reinforced fibers drawn from the reinforced fiber supply robot 30 to the table 22 while the reinforced fibers are adhered as the thermoplastic resin is melted. Particularly, the reinforced fiber supply robot 30 includes: a plurality of reels 33, around which the reinforced fibers F coated with the thermoplastic resin are wound; a plurality of supply rollers 34 configured to transfer the reinforced fibers F, drawn from the plurality of reels, to the table 22 to supply the reinforced fibers thereto; a cutter configured to cut the reinforced fibers F, supplied through the plurality of supply rollers 34, into a predetermined length; and a compression roller 37 configured to press the end of the reinforced fibers F, cut by the cutter, to the table 22.

The present invention provides a method of producing the composite comprising: a) melt blending the matrix with the fibers to produce a melted composite, b) injecting the melted composite into a mold and allowing the melted composite to solidify and, c) removing at least a portion of the outermost layer of a composite such that the fibers protrude from the surface of the composite. Also provided is composite produced by the methods of the invention comprising soft and hard fibers embedded in a soft rubber-like matrix, wherein the fibers protrude from the composite's surface. In specific embodiments, the composite comprises carbon fibers and poly(p-phenylene-2,6-benzobisoxazole) (PBO) fibers in a thermoplastic polyurethane (TPU) matrix, wherein the fibers protrude from the composite's surface. Slip-resistant product comprising the composite are also provided.

The present invention provides a method of producing the composite comprising: a) melt blending the matrix with the fibers to produce a melted composite, b) injecting the melted composite into a mold and allowing the melted composite to solidify and, c) removing at least a portion of the outermost layer of a composite such that the fibers protrude from the surface of the composite. Also provided is composite produced by the methods of the invention comprising soft and hard fibers embedded in a soft rubber-like matrix, wherein the fibers protrude from the composite's surface. In specific embodiments, the composite comprises carbon fibers and poly(p-phenylene-2,6-benzobisoxazole) (PBO) fibers in a thermoplastic polyurethane (TPU) matrix, wherein the fibers protrude from the composite's surface. Slip-resistant product comprising the composite are also provided.

A resin-based barrier comprises a body having a skin of fiber-reinforced resin. The body includes a top, a bottom, a front end, and a back end. A vertical shear web runs between the top and the bottom and is substantially perpendicular to the top and the bottom. Moreover, spaces between the vertical webbing and between the longitudinal webbing are filled with a high-density closed-cell foam. The barrier may be used as a temporary traffic barrier during road construction.

A resin-based barrier comprises a body having a skin of fiber-reinforced resin. The body includes a top, a bottom, a front end, and a back end. A vertical shear web runs between the top and the bottom and is substantially perpendicular to the top and the bottom. Moreover, spaces between the vertical webbing and between the longitudinal webbing are filled with a high-density closed-cell foam. The barrier may be used as a temporary traffic barrier during road construction.

A system for manufacturing a thermoplastic prepreg includes a double belt mechanism that is configured to compress a fiber mat, web, or mesh that is passed through the double belt mechanism, a resin applicator that is configured to apply monomers or oligomers to the fiber mat, web, or mesh, and a curing oven that is configured to effect polymerization of the monomers or oligomers and thereby form the thermoplastic polymer as the fiber mat, web, or mesh is moved through the curing oven. The double belt mechanism compresses the fiber mat, web, or mesh and the applied monomers or oligomers as the fiber mat, web, or mesh is passed through the curing oven so that the monomers or oligomers fully saturate the fiber mat, web, or mesh. Upon polymerization of the monomers or oligomers, the fiber mat, web, or mesh is fully impregnated with the thermoplastic polymer.

A system for manufacturing a thermoplastic prepreg includes a double belt mechanism that is configured to compress a fiber mat, web, or mesh that is passed through the double belt mechanism, a resin applicator that is configured to apply monomers or oligomers to the fiber mat, web, or mesh, and a curing oven that is configured to effect polymerization of the monomers or oligomers and thereby form the thermoplastic polymer as the fiber mat, web, or mesh is moved through the curing oven. The double belt mechanism compresses the fiber mat, web, or mesh and the applied monomers or oligomers as the fiber mat, web, or mesh is passed through the curing oven so that the monomers or oligomers fully saturate the fiber mat, web, or mesh. Upon polymerization of the monomers or oligomers, the fiber mat, web, or mesh is fully impregnated with the thermoplastic polymer.