A thermoplastic prepreg includes a mat, web, or fabric of fibers and hollow glass microspheres that are positioned atop the mat, web, or fabric of fibers or dispersed therein. The thermoplastic prepreg also includes a thermoplastic polymer that is fully impregnated through the mat, web, or fabric of fibers and the hollow glass microspheres so that the thermoplastic prepreg has a void content of less than 3% by volume of the thermoplastic prepreg. The thermoplastic material is polymerized monomers and oligomers in which greater than 90% by weight of the monomers or oligomers react to form the thermoplastic material.

An article includes a hybrid nanocomposite product, which includes a nanostructure array and a resin matrix contained among and/or around the nanostructure array. The array/matrix is placed in between layers of dry or resin-infused fiber composite to permit formation of a composite structure. The nanostructure array and/or the resin matrix may be disposed in an abutting relationship with other layers of a composite. The array/matrix can provide reinforcement of the composite in the z-direction. Transfer of resin into dry fiber forms may be provided when the array/matrix acts as a resin transfer medium. Nanostructure arrays with a resin matrix can be prepared to form a resin film product. Methods are presented for infusing composites via resin-transfer molding (RTM), vacuum-assisted resin transfer molding (VARTM), resin film infusion (RFI), or injection molding wherein a resin matrix film substantially maintains alignment and position of the nanostructure array during the infusion process.

A cylindrical winding body is formed by winding continuous fibers impregnated with a first thermosetting resin in a circumferential direction, and the first thermosetting resin in the winding body is thermally cured. A pair of dome members is joined to both end portions of the cylinder member. A fiber bundle impregnated with a second thermosetting resin is helically wound around the joined member over the dome members, and the second thermosetting resin in the wound fiber bundle is thermally cured. A thermosetting resin containing a main agent and a granular solid curing agent is used as the first thermosetting resin, the main agent including a resin precursor and the solid curing agent chemically bonding molecules of the resin precursor together.

A method of manufacturing a bicycle component having a component body formed at least partially of a fibrous composite material in a shaping mold. A shaping area of the shaping mold which serves to shape an outer section of the component body is provided with at least one intended surface roughness. At the same time, an intentional surface roughness is provided for the outer section by means of the surface roughness of the shaping area during manufacture of the outer section, to inhibit surface imperfections of the shaped outer section.

A method of curing an aircraft component including applying a temperature sensitive adhesive to a surface of a component, the surface having a contour; positioning a heating tool including a manifold with a ventilation path such that the ventilation path is adjacent to the surface by aligning the ventilation path to the contour of the component; and heating the surface of the component with uniform airflow from the ventilation path; wherein the manifold includes a chamber with a diverging portion configured to provide uniform airflow through the ventilation path to provide heating to the surface.

A method of joining segments of non-metallic pipe and an apparatus that may be used to form the joint. The pipes may be joined using by melting the ends to form a butt joint, then the joint may be wrapped with one or more sheets of reinforcement material (e.g., pre-impregnated fiberglass, carbon fiber, or aramid fiber). The reinforcement material may be heated using a heating apparatus which allows the material to bond to the pipes to strengthen the joint.

According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.

Embodiments of the present invention relate to a thermoplastic composite broadgood and a means of depositing a thermoplastic composite broadgood onto a mold. The broadgood may comprise of a plurality of separate, parallel strips of thermoplastic prepreg attached together by a plurality of delamination arresting elements. The broadgood may be deposited onto a mold by means of an apparatus comprising a plurality of flexible metal straps, each strap being configured to be heated. The straps may temporarily adhere to the broadgood when heated, thereby allowing the broadgood to be moved by means of the apparatus.

A method for manufacturing a panel for an aircraft is provided. The method includes arranging, on a curing surface, a skin of pre-preg composite material, arranging a plurality of pre-formed, uncured composite stringers, each having an open cross section with a web and a base transverse to each other so that a first base portion protrudes toward a first side and a second base portion protrudes toward a second side, arranging the stringers on the skin with the base in contact with the skin, arranging, on each stringer, a respective first mandrel to completely cover the first base portion and a respective second mandrel to completely cover the second base portion, and having the skin and the stringers undergo a co-curing process in autoclave with vacuum bag.

A composite material blank comprising an elongate blank body extending between a first end face and a second end face; said blank body extending in a longitudinal direction, parallel to a longitudinal axis thereof, and having four peripheral sides; each said first and second end face having edges which define a trapezoid shape; wherein the peripheral sides of said blank body connect the edges of said first end face with the edges of said second end face; and wherein said first trapezoid end face is inverted in relation to said second trapezoid end face. A method of manufacturing a composite blank, and a wind turbine blade root insert which may be formed from a blank.