The present invention is directed to a fiber cement felt comprising repeat units, each of which includes top, middle, and bottom machine direction yarns and cross-machine direction yarns interwoven with the top, middle, and bottom machine direction yarns in a predetermined weave pattern. The top, middle, and bottom machine direction yarns may comprise effect yarns and linear yarns without the need for a batt layer.

The present invention is directed to a fiber cement felt comprising repeat units, each of which includes top, middle, and bottom machine direction yarns and cross-machine direction yarns interwoven with the top, middle, and bottom machine direction yarns in a predetermined weave pattern. The top, middle, and bottom machine direction yarns may comprise effect yarns and linear yarns without the need for a batt layer.

Systems and methods for manufacturing unidirectional fiber prepreg tapes for CMC articles are provided. In one exemplary aspect, the method includes casting a matrix material on a carrier film to form a matrix film. The matrix material of the matrix film is then allowed to dry for a predetermined time. The matrix film is then wrapped on a drum and the matrix material is wet to a predetermined viscosity with a solvent. Thereafter, a fiber tow that includes of a plurality of fibers is wound about the drum so that the fiber tow penetrates into the matrix material and the matrix material impregnates the fiber tow to form the prepreg tape.

Systems and methods for manufacturing unidirectional fiber prepreg tapes for CMC articles are provided. In one exemplary aspect, the method includes casting a matrix material on a carrier film to form a matrix film. The matrix material of the matrix film is then allowed to dry for a predetermined time. The matrix film is then wrapped on a drum and the matrix material is wet to a predetermined viscosity with a solvent. Thereafter, a fiber tow that includes of a plurality of fibers is wound about the drum so that the fiber tow penetrates into the matrix material and the matrix material impregnates the fiber tow to form the prepreg tape.

An apparatus for making a composite article includes a monofilament feed track adapted to carry a spaced array of ceramic monofilament strands, a fiber yarn feed track adapted to carry a spaced array of fiber yarn tows impregnated with a plurality of glass particulates, a mandrel, and a heater assembly. The mandrel is adapted to wind together individual glass-impregnated fiber yarn strands and individual ceramic monofilament strands to form a dual-fiber weave. The heater assembly is adapted to heat at least the glass particulates such that pressure from the wound array of ceramic monofilaments is sufficient to consolidate the glass particulates and the dual-fiber weave into a dual-fiber ceramic matrix composite (CMC).

An apparatus for making a composite article includes a monofilament feed track adapted to carry a spaced array of ceramic monofilament strands, a fiber yarn feed track adapted to carry a spaced array of fiber yarn tows impregnated with a plurality of glass particulates, a mandrel, and a heater assembly. The mandrel is adapted to wind together individual glass-impregnated fiber yarn strands and individual ceramic monofilament strands to form a dual-fiber weave. The heater assembly is adapted to heat at least the glass particulates such that pressure from the wound array of ceramic monofilaments is sufficient to consolidate the glass particulates and the dual-fiber weave into a dual-fiber ceramic matrix composite (CMC).

A brick of cementitious fiber reinforced building material comprising may comprise a core surrounded by a mixture consisting essentially of about 40 wt % sand, about 5 wt % polymer, about 10 wt % water, about 32 wt % cement, about 8 wt % of a siliceous material, and about 3 wt % glass fiber. In some implementations, the core may be comprised of an expanded polystyrene (EPS) foam. The brick may optionally comprise at least one of a fiber glass mesh, a raceway, and a bonding agent.

A brick of cementitious fiber reinforced building material comprising may comprise a core surrounded by a mixture consisting essentially of about 40 wt % sand, about 5 wt % polymer, about 10 wt % water, about 32 wt % cement, about 8 wt % of a siliceous material, and about 3 wt % glass fiber. In some implementations, the core may be comprised of an expanded polystyrene (EPS) foam. The brick may optionally comprise at least one of a fiber glass mesh, a raceway, and a bonding agent.

An apparatus for making a composite article includes a monofilament feed track adapted to carry a spaced array of ceramic monofilament strands, a fiber yarn feed track adapted to carry a spaced array of fiber yarn tows impregnated with a plurality of glass particulates, a mandrel, and a heater assembly. The mandrel is adapted to wind together individual glass-impregnated fiber yarn strands and individual ceramic monofilament strands to form a dual-fiber weave. The heater assembly is adapted to heat at least the glass particulates such that pressure from the wound array of ceramic monofilaments is sufficient to consolidate the glass particulates and the dual-fiber weave into a dual-fiber ceramic matrix composite (CMC).

An apparatus for making a composite article includes a monofilament feed track adapted to carry a spaced array of ceramic monofilament strands, a fiber yarn feed track adapted to carry a spaced array of fiber yarn tows impregnated with a plurality of glass particulates, a mandrel, and a heater assembly. The mandrel is adapted to wind together individual glass-impregnated fiber yarn strands and individual ceramic monofilament strands to form a dual-fiber weave. The heater assembly is adapted to heat at least the glass particulates such that pressure from the wound array of ceramic monofilaments is sufficient to consolidate the glass particulates and the dual-fiber weave into a dual-fiber ceramic matrix composite (CMC).