An enclosure part for an information handling system is disclosed that may include materials formed together into a rectangular shape. The enclosure part may have a void on a core side and a flatness equal to or less than 0.5 mm. The materials may include a sheet of carbon fiber, a piece of non-woven carbon fiber, and a piece of non-woven glass fiber. A method for manufacturing an enclosure part using through-plane temperature control may include inserting into a mold a sheet of carbon fiber and a piece of non-woven carbon fiber, heat pressing the sheet of carbon fiber with the piece of non-woven carbon fiber, and cooling a first portion of the mold including the sheet of carbon fiber and the piece of non-woven carbon fiber more quickly than a second portion of the mold including the sheet of carbon fiber, and removing the enclosure part from the mold.

A rigid nylon porous material sheet is produced by the adhesive bonding of kinked nylon fibers having lengths of 1 to 5 inches. These fibers are cut from melt spun nylon or harvested from clean carpet fibers by shearing. The adhesive used is glycol, which attacks nylon at 180 C. forming a gel on the surface of the kinked fibers, but does not attack the nylon fibers when the kinked fiber assembly is cooled to 150 C. to precipitate ultrafine nylon within the gel. The fiber assembly is heated to 160 C. to bond the nylon fibers. It is then washed in hot water to remove unused glycol. The other adhesive is polyurethane, which is applied to the kinked fibers using coupling agents of aqueous resorcinol and vinyl pyrrolidone.

A structural reinforcement for an article including a carrier (10) that includes: (i) a mass of polymeric material (12) having an outer surface; and (ii) at least one fibrous composite Insert (14) or overlay (980) having an outer surface and including at least one elongated fiber arrangement (e.g., having a plurality of ordered fibers). The fibrous Insert (14) or overlay (980) is envisioned to adjoin the mass of the polymeric material in a predetermined location for carrying a predetermined load that Is subjected upon the predetermined location (thereby effectively providing localized reinforcement to that predetermined location). The fibrous insert (14) or overlay (980) and the mass of polymeric material (12) are of compatible materials, structures or both, for allowing the fibrous insert or overlay to be at least partially joined to the mass of the polymeric material. Disposed upon at least a portion of the carrier (10) may be a mass of activatable material (126). The fibrous insert (14) or overlay (980) may include a polymeric matrix that includes a thermoplastic epoxy.

According to some aspects, a method of additive fabrication is provided wherein a plurality of layers of material are formed on a build platform, the method comprising forming a layer of material in contact with a substrate and further in contact with either a previously formed layer of material or the build platform, the substrate being an actinically transparent, flexible, composite material, and subsequent to the forming of the layer of the material, actively separating the layer of material from the substrate.

An enclosure part for an information handling system is disclosed that may include materials formed together into a rectangular shape. The enclosure part may have a void on a core side and a flatness equal to or less than 0.5 mm. The materials may include a sheet of carbon fiber, a piece of non-woven carbon fiber, and a non-woven glass fiber. A method for manufacturing an enclosure part using through-plane temperature control may include inserting into a mold a sheet of carbon fiber and a piece of non-woven carbon fiber, heat pressing the sheet of carbon fiber with the piece of non-woven carbon fiber, and cooling a first portion of the mold including the sheet of carbon fiber and the piece of non-woven carbon fiber more quickly than a second portion of the mold including the sheet of carbon fiber, and removing the enclosure part from the mold.

A molding process includes the operation of placing insulation material comprising fibers and binder on the fibers in a mold cavity. The molding process further includes the operation of transferring heat to the insulation material to cause the binder to cure.

A method of producing a headliner with a unitary body includes the steps of thermoforming a blank into a headliner substrate, simultaneously injection molding a secondary component onto the headliner substrate and laminating a surface covering to the headliner substrate.

A structural reinforcement for an article including a carrier (10) that includes: (t) a mass of polymeric material (12) having an outer surface; and (ii) at least one fibrous composite Insert (14) or overlay (980) having an outer surface and including at least one elongated fiber arrangement (e.g., having a plurality of ordered fibers). The fibrous Insert (14) or overlay (980) is envisioned to adjoin the mass of the polymeric material in a predetermined location for carrying a predetermined load that Is subjected upon the predetermined location (thereby effectively providing localized reinforcement to that predetermined location). The fibrous insert (14) or overlay (980) and the mass of polymeric material (12) are of compatible materials, structures or both, for allowing the fibrous insert or overlay to be at feast partially joined to the mass of the polymeric material. Disposed upon at least a portion of the carrier (10) may be a mass of activatable material (126). The fibrous insert (14) or overlay (980) may include a polymeric matrix that includes a thermoplastic epoxy.

A method for preparing a construction board, the method comprising (i) providing a non-woven mat having a coating layer disposed on a planar surface thereof, where the coating layer includes an inorganic filler dispersed within a polymeric matrix; (ii) contacting an A-side stream of reactants including an isocyanate compound with a B-side stream of reactants including an isocyanate-reactive compound to prepare a developing foam; and (iii) depositing the developing foam on to said coating of said non-woven mat.

An object of the present invention is to provide a fiber-reinforced composite material achieving both lightweight properties and mechanical properties, a laminate thereof, and a prepreg capable of easily molding a sandwich structure thereof. The present invention is a prepreg comprising a reinforced fiber substrate (B) impregnated with a resin (A), wherein the reinforced fiber substrate (B) exists in a folded state having a plurality of folds with a fold angle of 0 or more and less than 90 in the prepreg.