The present invention relates to processes and apparatuses for producing hydrophobized fiber cement sheets as well as fiber cement sheets obtainable therewith. In particular, the present invention provides processes for manufacturing a hydrophobized fiber cement product, said process at least comprising the steps of: (i) forming at least one fiber cement film on a rotating sieve in contact with a fiber cement slurry in a vat; (ii) transferring said at least one fiber cement film from said sieve to a felt transport belt, (iii) applying a mist of a hydrophobizing agent to said at least one fiber cement film, and (iv) accumulating the fiber cement film on an accumulator roll via the felt transport belt, so as to form a hydrophobized fiber cement product. The present invention further relates to various uses of the fiber cement sheets obtainable by the processes of the invention in the building industry.

A resin formulation is disclosed. The resin formulation includes, before cure, at least one polymer derived ceramic (PDC) resin, and carbon fibers. The carbon fibers may include one or more metals. The resin formulation may be at least substantially free of a solvent. Related articles and methods are also disclosed.

A resin formulation is disclosed. The resin formulation includes, before cure, at least one polymer derived ceramic (PDC) resin, and carbon fibers. The carbon fibers may include one or more metals. The resin formulation may be at least substantially free of a solvent. Related articles and methods are also disclosed.

A tooling assembly for use in forming z-channels in a fibrous ceramic preform includes a mandrel having a first plurality of holes extending into a mandrel body, a first subset of the plurality of holes being through-holes extending completely through the mandrel, and a second subset of the holes comprising blind pockets, and a plurality of channels extending longitudinally along the mandrel in a direction orthogonal to the first plurality of holes. The tooling assembly further includes an outer fixture at least partially enclosing the mandrel, the outer fixture including at least one piece comprising a second plurality of holes extending completely through the at least one piece, the second plurality of holes being aligned with respective corresponding ones of the first plurality of holes such that a needle can be inserted through each of the second plurality of holes in the at least one piece and into the respective ones of the first plurality of holes in the mandrel.

A tooling assembly for use in forming z-channels in a fibrous ceramic preform includes a mandrel having a first plurality of holes extending into a mandrel body, a first subset of the plurality of holes being through-holes extending completely through the mandrel, and a second subset of the holes comprising blind pockets, and a plurality of channels extending longitudinally along the mandrel in a direction orthogonal to the first plurality of holes. The tooling assembly further includes an outer fixture at least partially enclosing the mandrel, the outer fixture including at least one piece comprising a second plurality of holes extending completely through the at least one piece, the second plurality of holes being aligned with respective corresponding ones of the first plurality of holes such that a needle can be inserted through each of the second plurality of holes in the at least one piece and into the respective ones of the first plurality of holes in the mandrel.

A method of preparing a ceramic fabric for use in a ceramic matrix composite includes transforming a ceramic tow from a first tow geometry to a second tow geometry, thereby reducing a first dimension of the ceramic tow and increasing a second dimension of the ceramic tow orthogonal to the first dimension to produce a flattened tow. The method includes weaving or braiding the flattened ceramic tow to form a ceramic fabric.

A method of preparing a ceramic fabric for use in a ceramic matrix composite includes transforming a ceramic tow from a first tow geometry to a second tow geometry, thereby reducing a first dimension of the ceramic tow and increasing a second dimension of the ceramic tow orthogonal to the first dimension to produce a flattened tow. The method includes weaving or braiding the flattened ceramic tow to form a ceramic fabric.

The present invention relates to a layered formed sheet comprising two or more formed sheets each formed from a curable composition comprising (A) an aluminosilicate source, (B) an alkaline metal hydroxide, (C) cellulose-based fibers and (D) alkali-resistant fibers other than cellulose-based fibers, in which the aluminosilicate source (A) comprises a blast furnace slag, and the content of a blast furnace slag having a specific surface area of 1000 cm.sup.2/g or more and 9000 cm.sup.2/g or less is more than 55% by mass and 90% by mass or less related to a total solid content in the curable composition.

The present invention relates to a layered formed sheet comprising two or more formed sheets each formed from a curable composition comprising (A) an aluminosilicate source, (B) an alkaline metal hydroxide, (C) cellulose-based fibers and (D) alkali-resistant fibers other than cellulose-based fibers, in which the aluminosilicate source (A) comprises a blast furnace slag, and the content of a blast furnace slag having a specific surface area of 1000 cm.sup.2/g or more and 9000 cm.sup.2/g or less is more than 55% by mass and 90% by mass or less related to a total solid content in the curable composition.

A plastic encased mandrel includes an open cell carbonaceous foam that is shaped to correspond to a core of a ceramic matrix composite (CMC) part. A polyvinyl butyral (PVB) plastic is injection molded into the carbonaceous foam, before or after shaping, to encase the carbonaceous foam core and form an encased mandrel. The open cell carbonaceous foam may be silicon carbide (SiC) foam or reticulated vitreous carbon (RVC) foam. The foam core may be incorporated into the CMC part when SiC foam is used for better distribution of thermal and structural loads or the foam core may be removed from the CMC part when RVC foam is used, such as when a CMC vane incorporates a metal spar.