A process for forming defect-free fibrous composite materials. More particularly, a process for forming blister-free fibrous composites without having to actively monitor or control blister formation during molding of a stack of plies, and to blister-free composite materials fabricated therefrom. Fibrous plies are coated with a dry, particulate binder without impregnating the plies with the binder. Gaps between fibers/tapes allow air to diffuse out of the stack without affecting the binder coating, thereby avoiding blister formation.

Disclosed are methods for utilizing reclaimed carpet materials in the manufacture of high density composites. Also disclosed are products manufactured by the disclosed methods.

An impregnation system and a method for impregnating a textile fabric for composite components are described. A matrix 2 can be applied to a textile fabric 1 in such a way that the matrix 2 penetrates it at least partially and/or at least on one side. A first and a second endless belt 1 each designed as a belt loop are provided for the impregnation system. Between the first 4 and the second belt loop 5, the textile fabric 1 can guided on the mutually facing surfaces 6 of the belt loops and can be impregnated there. The deflection rollers 7 are provided in the respective belt loop 4, 5 of the respective endless belts at the deflection areas, with at least one roller being adjustable in the direction of the mutually facing surfaces 6 of the belt loops 4, 5. By adjusting the rollers 8 in the y direction, the wrap angle and thus the pressure exerted on the textile fabric during impregnation is controlled.

A method for controlling the thickness of a continuous elongated element made of elastomeric material, applied according to coils wound on a forming support, includes: advancing a head end of the continuous elongated element toward the forming support; subjecting, during the advancement, the continuous elongated element to a first stretching with a first stretch coefficient before applying on the forming support; and subjecting, during the advancement, the continuous elongated element to a second stretching with a second stretch coefficient during the application on the forming support. During the first stretching, a span of the continuous elongated element adjacent to the head end is stretched with a supplementary stretch coefficient greater than the first stretch coefficient, in a manner so as to confer, also to the span adjacent to the head end, a stretch and a section similar or substantially equivalent to those of the rest of the continuous elongated element.

A compression apparatus (10) for compressing a tubular structure (12) to be formed into a hollow structure (20) such as a pipe comprises contact elements (60) arranged in two sets, (61, 62). The contact elements (60) are adapted to move along a compression section (41) in a coordinated sequence, whereby a portion (12a) of the tubular structure (12) within the compression section (41) is compressed between pairs (63) of opposed contact elements. The apparatus (10) includes registration means (110) for causing respective pairs (63) of opposed contact elements (60) to be maintained in registration with each other while moving along the compression section (41).

A method for making a floor or wall panel has a foamed polymer core. A foamable polymer powder is foamed between two conveyor belts in the forming zone of a steel belt press. The sum of the thicknesses of the two conveyor belts and the total thickness of the layers at the entrance of the steel belt press is less than or equal to the opening of the steel belt press at the entrance of the steel belt press. The sum of the thicknesses of the two conveyor belts and the total thickness of the substrate at the outlet of the steel belt press is equal to the opening of the steel belt press at the outlet of the steel belt press and greater than the sum of the thicknesses of the two conveyor belts and the total thickness of the layers at the entrance of the steel belt press.

A carrier material for producing a decorated wall or floor panel, as well as the corresponding wall or floor panel, may comprise a matrix material and a solid material. The matrix material is present from ≥25 wt.-% to ≤55 wt.-% and the solid material is present from ≥45 wt.-% to ≤75 wt.-% of the carrier material. The matrix material and the solid material together may be present in an amount of ≥95 wt.-% of the carrier material. The solid material is formed to at least 50 wt.-% of a solid composition consisting of at least a first layered silicate powder and a second layered silicate powder. The matrix material is formed to at least 50 wt.-% by a plastic composition consisting of a homopolymer and at least a first copolymer and a second copolymer.

A panel for forming a floor covering has a substrate including at least a layer of thermoplastic material, where the panel, above the layer, has at least also a printed décor and a translucent or transparent wear layer. The layer also includes at least individual fibers having a length greater than 1 millimeter, where the individual fibers are loose and freely distributed with the layer of thermoplastic material.

Provided is a method for manufacturing a molded article obtained by double belt press molding a thermosetting prepreg, in which the thermosetting prepreg is coated with a release film during molding, and a width of the prepreg is 1 to 25 mm smaller than that of the release film. This manufacturing method suppresses burr generation and fiber twisting, and is excellent in width restriction, and thus can be suitably used for, for example, automobile members, railroad vehicle members, aerospace machine members, ship members, household equipment members, sporting goods members, light vehicle members, building and civil engineering members, and housings for OA equipment and the like.

Floor panel for forming a floor covering, where the floor panel includes a carrier on the basis of a thermoplastic material and a top layer provided on the carrier. The thermoplastic material is free from plasticizers or includes a plasticizer in an amount up to maximum 20 phr, where the thermoplastic material is foamed or expanded, and where the carrier is provided with a reinforcement layer.