Embodiments of the present invention provide a self-molding composite system for insulation and covering operations. The self-molding composite system may be cured to form any desired shaped for insulation and covering operations. The composite system comprises one or more layers that may create a rigid layered composite when cured. The one or more layers of the composite system may include a base layer that is a braided, knit, or non-woven fiber based substrate, an interstitial matrix layer, and customizable top coat. The customizable top coat may be a solvent based polymer solution that includes various additives that may include color pigments, additives for additional abrasion protection, additives for thermal protection, and/or additives for creating various textures or visible appearances to the composite system.

Embodiments of the present invention provide a self-molding composite system for insulation and covering operations. The self-molding composite system may be cured to form any desired shaped for insulation and covering operations. The composite system comprises one or more layers that may create a rigid layered composite when cured. The one or more layers of the composite system may include a base layer that is a braided, knit, or non-woven fiber based substrate, an interstitial matrix layer, and customizable top coat. The customizable top coat may be a solvent based polymer solution that includes various additives that may include color pigments, additives for additional abrasion protection, additives for thermal protection, and/or additives for creating various textures or visible appearances to the composite system.

A process is provided for producing a stable fabric comprising: 1) providing a first fabric formed from reinforcing fibers, 2) providing a nonwoven web produced from fibers, having softening temperature lower than said reinforcing fibers, on at least 1 one side of said first fabric to form a structure, 3) heating said structure to a temperature between the softening temperature and melting temperature of said nonwoven web, and 4) cooling said structure to thereby provide a stable two-dimensional fabric. In a preferred embodiment, the structure of step 2) is put into a mold prior to heating step 3), heating said structure in the mold according to step 3), cooling said structure in the mold according to step 4) and thereby providing a three-dimensional shaped article. A product is also provided produced by these processes.

A multi-layer braided article and a method of making the multi-layer braided article. The multi-layer braided article includes a braid extending along a first axis, wherein the braid is folded over itself to form a first layer and a second layer; and a wrapper laid over the first layer of the braid and extending circumferentially around the first axis, wherein the wrapper defines an edge of the first layer about which the braid is folded. The multi-layer braided article may form part of a blade for an aircraft. A sleeve may be provided around a conical portion of the article to connect the article to something else, such as a propeller hub, where the multi-layer braided article is formed as part of a blade. The sleeve may provide a primary or secondary load path.

Described are continuous fiber-reinforced composites that include a self-healing copolymer. The continuous fiber-reinforced composites are used to form self-healing products. Products include multi-layer hoses that include a self-healing layer. The self-healing layer can be sandwiched between an inner layer and an outer layer of a multi-layer hose, thus forming a self-healing multi-layer hose. Multi-layers hoses can be utilized as self-healing hydrogen dispensing hoses. Methods for forming the continuous fiber-reinforced composites and products are also described.

Techniques are directed to providing a carbon composite product. Such techniques involve providing a bias pattern fabric that extends from a starting side along a run direction, the bias pattern fabric including carbon fiber threads oriented diagonally relative to the run direction. Such techniques further involve impregnating the bias pattern fabric with resinous material to form a run of prepreg material. Such techniques further involve cutting the run of prepreg material lengthwise to the run direction to form multiple tapes.