A prepared mold tool having a thermoplastic surface layer polymer coating on the mold surface of the mold tool or prepared prepreg having a thermoplastic surface layer polymer coating on the surface of the thermoplastic fiber reinforced prepreg are described that enhance first ply laydown of thermoplastic fiber reinforced composite prepregs onto mold tools for prepreg forming or in situ tape placement. Resulting thermoplastic fiber reinforced composite parts from a thermoplastic fiber reinforced thermoplastic composite material having structural reinforcement fibers with one or more high performance polymers, and a thermoplastic surface layer polymer coating which forms a polymer blend with the high performance polymers of the thermoplastic fiber reinforced composite material thereby imparting improved properties, and methods for making and using same, are provided herein.

The present disclosed subject matter relates to a method for producing a composite component, in particular for a gliding board, roller board or skateboard. The method comprises introducing a bottom mat made of reinforcing fibers, above this a flat core made of plastic, and above this a top mat made of reinforcing fibers into an opened mold, closing the mold, introducing an uncured plastics matrix into the closed mold, allowing the plastics matrix to cure in the closed mold, opening the mold, and demolding the composite component. The core is provided on its lower and upper sides with a plurality of spacer nubs, which keep the bottom and top mats in the closed mold at a distance from the lower and upper sides.

The present invention relates to a tool (W) having at least one first inlet opening (E1) and at least one second inlet opening (E2), and also at least one first outlet opening (A1), at least one second outlet opening (A2) and at least one third outlet opening (A3), wherein the second outlet opening (A2) and the third outlet opening (A3) alternate with the first outlet opening (A1). The present invention further relates to a process for producing a fiber/foam composite by extruding through the tool (W) and to the use of the tool (W) for production of a fiber/foam composite by extrusion.

A method for manufacturing a part made of composite material for a turbomachine, in particular of an aircraft, includes the steps of: b) arranging a preform made of fibers in a mold, c) injecting polymerizable resin into the mold, d) machining the part, and e) visually checking the part. Step b) is preceded by a step a) in which at least one compliance coating is deposited in the mold. The compliance coating has a calibrated thickness (X) and at least one visual aspect identifiable by an operator. The coating is configured to cover at least one area of the preform and to be rigidly attached thereto by the resin at the end of step c) Step e) includes verifying, by the operator, the presence of the aspect in the area.

A system for forming an article includes a polymer resin formulation formed of a semicrystalline polymer material having a first fiber content and an amorphous polymer material having a second fiber content. The first fiber content is higher than the second fiber content. Further, the semicrystalline and amorphous polymer materials are blended together to form the polymer resin formulation having a blended fiber content of greater than 10% by weight. Moreover, the polymer resin formulation is amorphous. The system also includes a computer numeric control (CNC) device for printing and depositing the polymer resin formulation layer by layer to form the article.

A building product for application to the exterior of a building. The front face of the product utilizes a first fiber sheet partially embedded within a thermoset polymer coating resin. A foamed closed cell admixture composition core with an inorganic filler overlays the thermoset polymer coating resin with the embedded fiber sheet. The admixture composition infiltrates and bonds to the portion of the fiber sheet that is not embedded within the thermoset polymer coating resin mechanically bonding to the thermoset polymer coating. A second fiber sheet overlays the admixture core and the admixture and second fiber sheet form the rear surface of the building product that is mounted adjacent the building surface.

A composite structural panel for use in bridge structures, and method of manufacturing same, comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross-sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.

The present invention concerns Method for producing a unidirectional tape, the method comprising the steps of a) providing an impregnation slurry comprising primary particles and secondary particles, water, optionally an organic carrying medium, optionally an organic compound and optionally a surface active compound, and providing a unidirectional fiber layer having an average interstitial filament distance, wherein the primary particles comprise a first polymer and the primary particles have a particle size equal to or smaller than the average interstitial filament distance, and the secondary particles comprise a second polymer and the secondary particles have a particle size larger than the average interstitial filament distance, b) impregnating the unidirectional fiber layer with the impregnation slurry to form an impregnated unidirectional fiber web comprising an impregnated unidirectional fiber layer and a surface polymer layer, wherein the impregnated unidirectional fiber layer comprises, preferably consists of, the unidirectional fibers and the primary particles, and the surface polymer layer comprises the secondary particles, c) drying the impregnated unidirectional fiber web to obtain a unidirectional tape.

Provided is a technology for imparting a design having a higher degree of freedom than in the related art to a composite material product including a woven fabric, which is formed of a thread made of a specific fiber (carbon fiber, glass fiber, aramid fiber), and a resin. As a first step, a specific fiber cloth (100), which is the woven fabric formed of the thread made of a specific fiber, and a backing sheet (200) formed of a thermoplastic resin are stacked. Subsequently, embroidery is performed with an embroidery thread (300) to form a design on a front surface of the specific fiber cloth (100). The embroidery thread (300) is made of the specific fiber, and penetrates through the specific fiber cloth (100) and the backing sheet (200). Then, the specific fiber cloth (100) and the backing sheet (200) are sandwiched between resin sheets (400) each formed of a thermoplastic resin, and the whole is cured by an RFI method.

An automated manufacturing method and system and in-mold coated plastic article produced thereby are provided. The system includes a compression mold and a plurality of program-controlled manipulators. An automatic sprayer supported on a first manipulator sprays at least a portion of a mold surface with an in-mold coating composition. An end effector supported on a second manipulator picks up a heated blank of moldable plastic sheet material from an oven and places the heated blank between upper and lower mold halves of the mold. An inner portion of the heated blank is forced into an article-defining cavity of the mold and into contact with at least a portion of the in-mold coating composition. The in-mold coating composition and the inner portion of the heated blank cure and bond to one another so as to form the coated plastic article.