This disclosure relates to an in-mold surfacing film for structural composites, in the form of a thermally curable mul-ti-layer film comprising: (a) a release carrier, (b) a surfacing film layer overlying the release carrier, wherein the surfacing film layer comprises an OH-functional polyurethane and a thermally activatable curing agent which can react with the OH groups at a temperature higher than 120° C., and (c) a release liner. Also disclosed is a method for preparing a composite article in-mold using a prepreg and the multi-layer film.

This disclosure relates to an in-mold surfacing film for structural composites, in the form of a thermally curable mul-ti-layer film comprising: (a) a release carrier, (b) a surfacing film layer overlying the release carrier, wherein the surfacing film layer comprises an OH-functional polyurethane and a thermally activatable curing agent which can react with the OH groups at a temperature higher than 120° C., and (c) a release liner. Also disclosed is a method for preparing a composite article in-mold using a prepreg and the multi-layer film.

A method of making a ceramic fiber tow and the system regarding the same may be included. The method may include commingling a plurality of ceramic fibers with a fugitive fiber to form a single ceramic fiber tow. The fugitive fiber may be positioned between at least two ceramic fibers included in the single ceramic fiber tow. The method may further include forming a porous ceramic preform including at least the single ceramic fiber tow. The method may further include removing the fugitive fiber from the ceramic fiber tow leaving a space between at least two ceramic fibers of the single ceramic fiber tow. The method may further include replacing the spaces between ceramic fibers included in the ceramic fiber tows with a ceramic matrix.

A method of making a ceramic fiber tow and the system regarding the same may be included. The method may include commingling a plurality of ceramic fibers with a fugitive fiber to form a single ceramic fiber tow. The fugitive fiber may be positioned between at least two ceramic fibers included in the single ceramic fiber tow. The method may further include forming a porous ceramic preform including at least the single ceramic fiber tow. The method may further include removing the fugitive fiber from the ceramic fiber tow leaving a space between at least two ceramic fibers of the single ceramic fiber tow. The method may further include replacing the spaces between ceramic fibers included in the ceramic fiber tows with a ceramic matrix.

The machine comprises a solid matrix (1), a deformable body (2) joined to the surface of said matrix (1), a shaping mould (3) and a securing system system (5) for the fibre structure (4). The matrix (1) is a solid element having a functional face, the geometry of which depends on the part to be manufactured. The deformable body (2) has an initial geometry that depends on the geometry to be given to the fibre structure (4). The shaping mould (3) has the geometry to be given to the fibre structure (4) during the process of adaptation to the shaping mould (3), and the shaping mould (3) is located such that the deformable body (2) is located between said shaping mould (3) and the matrix (1).

A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.

A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.

The disclosure discloses a preparation method and product of carbon fiber reinforced polymer composites with a designable characteristic structure. The method includes: (a) choosing carbon fabrics as raw material, where a predetermined number of the fabrics are selected to deposit the reinforcement phase; (b) coating all carbon fabrics with resin matrix, placing the fabrics layer by layer, where the carbon fabrics with the reinforcement phases are placed in a predetermined layer, meanwhile a micro power supply is placed in a setting layer during the stacking process, then a prefabricated product is obtained; (c) placing the prefabricated product in a vacuum bag then evacuating and sealing, hot pressing the sealed prefabricated product, finally the carbon fiber reinforced polymer composite product in the vacuum bag after hot pressing is successfully manufactured.

The disclosure discloses a preparation method and product of carbon fiber reinforced polymer composites with a designable characteristic structure. The method includes: (a) choosing carbon fabrics as raw material, where a predetermined number of the fabrics are selected to deposit the reinforcement phase; (b) coating all carbon fabrics with resin matrix, placing the fabrics layer by layer, where the carbon fabrics with the reinforcement phases are placed in a predetermined layer, meanwhile a micro power supply is placed in a setting layer during the stacking process, then a prefabricated product is obtained; (c) placing the prefabricated product in a vacuum bag then evacuating and sealing, hot pressing the sealed prefabricated product, finally the carbon fiber reinforced polymer composite product in the vacuum bag after hot pressing is successfully manufactured.

Disclosed is a cover for a utility vault and a method for making such covers. The cover is formed from fiberglass reinforcement layers and a polymer mix matrix. The reinforcement layers include a bottom reinforcement layer, one or more edge reinforcement layers, and a top reinforcement layer. A first portion of the edge reinforcement layer overlaps a portion of the bottom reinforcement layer and a second portion of the edge reinforcement layer overlaps a portion of the top reinforcement layer. The reinforcement layers are formed from fiberglass fabric and may include fiberglass layers whose fibers are oriented quadraxially. The polymer mix impregnates the fabric layers and forms the bulk of the cover. The polymer matrix bonds the reinforcement layers so that forces applied across the top and bottom layers are communicated to the edge reinforcement layer. The polymer matrix includes a thermoset polymer resin and an expanded glass bead filler.