Provided is a method of manufacturing a FRP product that is obtained by integrally curing a prepreg where fibers are arranged in a specific direction, such as a unidirectional prepreg, a cloth prepreg, or a tow prepreg and a chopped fiber prepreg, such as a sheet molding compound, in which disorder of fiber arrangement in a portion obtained by curing the prepreg is suppressed to obtain an expected strength.

A panel structure (10A) includes a substrate portion (11) and at least two ribs (12) standing on the substrate portion (11) and intersecting with each other. A substrate material portion (24) constituting the substrate portion (11) is formed by using at least matrix resin. Continuous fibers or slit continuous fibers are arranged at a position corresponding to the ribs (12) and a rib intersecting portion (13).

An example composite building material includes one or more layers of polymeric fibers, binding agent, and optional fillers, and at least one surface layer of resin-impregnated paper disposed above and/or below the one or more layers. The one or more layers can include a core layer with longer polymeric fibers and top and bottom layers with shorter polymeric fibers. A method of manufacturing the composite building material includes forming the one or more layers, applying the at least one surface layer above and/or below the one or more layers, and heating and pressing the combined layers.

A method of cosmetically altering a fiberglass piece comprising having a graphical element disposed on a layer of textile fabric. An outer layer of a curable gel-coat is applied to a mold for the cosmetically altered fiberglass piece. At least one intermediate layer of textile is then applied over the outer layer, the textile comprising a graphical element disposed adjacent to the outer layer. An inner layer is then applied to the intermediate layer, the inner layer providing structural support to the fiberglass piece. A bonding agent is then applied to wet out the outer layer, the intermediate layer, and the inner layer, thereby resulting in an assembly of a wet out three-layer combination, the curing of which results in the cosmetically altered fiberglass piece.

A base material is provided for molding in which reinforcing fibers are oriented at three or more different orientation angles. In this base material, the reinforcing fibers oriented at one or two of the three or more orientation angles are continuous fibers, and the reinforcing fibers oriented at the other orientation angles are discontinuous fibers.

A composite material shell having a base plate made of thermoplastic resin and reinforcing fibers and multiple decorative pieces. Each of the multiple decorative pieces is made of a composite material containing thermoplastic resin and reinforcing fibers. An area of each of the multiple decorative pieces is smaller than an area of the base plate, wherein the multiple decorative pieces are non-directionally arranged, are overlapped, and are welded on the base plate whereby the composite material shell provides unique reflection and depth variations of visual effect.

A threaded medical implant comprising a biocomposite, said biocomposite comprising a polymer and a plurality of reinforcement fibers, wherein a weight percentage of a mineral composition within the biocomposite medical implant is in the range of 30-60%, wherein an average diameter of said fibers is in a range of 1-100 microns, said medical implant being threaded with a plurality of threads; wherein said fibers comprise a plurality of helical fibers and a plurality of longitudinal fibers; wherein a weight to weight percent ratio of said helical to said longitudinal fibers is from 90:10 to 10:90.

Composite components, such as gas turbine engine airfoils, and methods of forming composite components are provided. For example, a composite component of a gas turbine engine comprises a plurality of continuous fiber layers, each continuous fiber layer formed from a plurality of continuous fibers disposed in a matrix material, and a chopped fiber layer comprising a plurality of chopped fibers formed as a filmed sheet. The chopped fiber layer is laid up with the plurality of continuous fiber layers to form the composite component. A method for forming a composite component comprises laying up a plurality of continuous fiber layers, each continuous fiber layer comprising continuous fibers disposed in a matrix material; laying up a chopped fiber layer with the plurality of continuous fiber layers, the layup of the plurality of continuous fiber layers and the chopped fiber layer forming a reinforced layup; and curing the reinforced layup.

The present invention relates to a plastic based high density wood fiber composite (HDWFC) product and a method for manufacturing said composite product. The invention also relates to an apparatus for manufacturing said composite product.

A rib-stiffened composite structure includes a composite face sheet having a continuous reinforcing fiber in a polymer matrix. A polymer core is in a grid pattern disposed on the composite face sheet, the grid pattern having a first series of paths crossing over a second series of paths. Material voids are formed in the spaces between the series of paths. A composite rib-cap is disposed upon an upper surface of the polymer core. The composite rib-cap includes a continuous reinforcing fiber in a polymer matrix. The fibers of the continuous reinforcing fiber of the polymer matrix of the composite rib cap are oriented in a direction along the first and second series of paths of the grid pattern of the extruded polymer core.