Methods of making fiber-containing prepregs are described. The methods may include the steps of providing a plurality of fibers, and applying a reactive resin composition to the plurality of fibers to make a mixture of the plurality of fibers and the resin composition. The reactive resin composition may include at least one of monomers and oligomers capable of polymerizing into a polymerized resin matrix. The mixture may be heated to a polymerization temperature where the monomers, oligomers, or both polymerize to form a fiber-resin amalgam that includes the polymerized resin matrix. The fiber-resin amalgam may be formed into the fiber-containing prepreg. Also described are methods of forming a fiber-reinforced composite that includes the prepreg.

The present disclosure relates to a prepreg, a preparation method thereof and a fiber-reinforced composite material prepared therefrom. The preparation method of a prepreg may include an aramid fiber base material with improved wettability to resin, can increase a thickness reduction rate during molding of the prepreg, has an appropriate resin content, and can provide a prepreg suitable for molding by an out-of-autoclave process. In addition, the prepreg may provide a fiber-reinforced composite material that exhibits a thin thickness and a high resin content even by an out-of-autoclave process, and shows high strength and low moisture absorption

The present disclosure relates to a prepreg, a preparation method thereof and a fiber-reinforced composite material prepared therefrom. The preparation method of a prepreg may include an aramid fiber base material with improved wettability to resin, can increase a thickness reduction rate during molding of the prepreg, has an appropriate resin content, and can provide a prepreg suitable for molding by an out-of-autoclave process. In addition, the prepreg may provide a fiber-reinforced composite material that exhibits a thin thickness and a high resin content even by an out-of-autoclave process, and shows high strength and low moisture absorption

A system for manufacturing a thermoplastic prepreg includes a double belt mechanism that is configured to compress a fiber mat, web, or mesh that is passed through the double belt mechanism, a resin applicator that is configured to apply monomers or oligomers to the fiber mat, web, or mesh, and a curing oven that is configured to effect polymerization of the monomers or oligomers and thereby form the thermoplastic polymer as the fiber mat, web, or mesh is moved through the curing oven. The double belt mechanism compresses the fiber mat, web, or mesh and the applied monomers or oligomers as the fiber mat, web, or mesh is passed through the curing oven so that the monomers or oligomers fully saturate the fiber mat, web, or mesh. Upon polymerization of the monomers or oligomers, the fiber mat, web, or mesh is fully impregnated with the thermoplastic polymer.

A system for manufacturing a thermoplastic prepreg includes a double belt mechanism that is configured to compress a fiber mat, web, or mesh that is passed through the double belt mechanism, a resin applicator that is configured to apply monomers or oligomers to the fiber mat, web, or mesh, and a curing oven that is configured to effect polymerization of the monomers or oligomers and thereby form the thermoplastic polymer as the fiber mat, web, or mesh is moved through the curing oven. The double belt mechanism compresses the fiber mat, web, or mesh and the applied monomers or oligomers as the fiber mat, web, or mesh is passed through the curing oven so that the monomers or oligomers fully saturate the fiber mat, web, or mesh. Upon polymerization of the monomers or oligomers, the fiber mat, web, or mesh is fully impregnated with the thermoplastic polymer.

A method for manufacturing an impregnated fibrous material comprising at least one fibrous material made of continuous fibres and at least one thermoplastic polymer matrix comprises a step of pre-impregnating the fibrous material with a thermoplastic polymer matrix in powder form. This step is carried out dry in a tank comprising a fluidized bed, while keeping the level h of the powder and the mass m of the powder present in the tank substantially constant. The level h is from hi to hi−3%, during implementation of the pre-impregnation step, and hi is the initial level of the powder in the tank at the start of implementation of the pre-impregnation step, the mass m is from mi to mi±0.5% during implementation of the pre-impregnation step, and mi is the initial mass of the powder in the tank at the start of implementation of the pre-impregnation step.

A method for manufacturing an impregnated fibrous material comprising at least one fibrous material made of continuous fibres and at least one thermoplastic polymer matrix comprises a step of pre-impregnating the fibrous material with a thermoplastic polymer matrix in powder form. This step is carried out dry in a tank comprising a fluidized bed, while keeping the level h of the powder and the mass m of the powder present in the tank substantially constant. The level h is from hi to hi−3%, during implementation of the pre-impregnation step, and hi is the initial level of the powder in the tank at the start of implementation of the pre-impregnation step, the mass m is from mi to mi±0.5% during implementation of the pre-impregnation step, and mi is the initial mass of the powder in the tank at the start of implementation of the pre-impregnation step.

A method for fabricating a composite wing structural component for an aircraft is described. The method comprises extruding a filler material into each mold channel of a plurality of mold channels of a die to form a plurality of filler segments, removing the plurality of filler segments from the plurality of mold channels of the die, and arranging the plurality of filler segments in a space in the composite structural component, the space being defined by a radius of the composite structural component, such that the filler segments are in end-to-end contact. The method further comprises curing the plurality of filler segments in the space to fuse the plurality of filler segments.

A method for fabricating a composite wing structural component for an aircraft is described. The method comprises extruding a filler material into each mold channel of a plurality of mold channels of a die to form a plurality of filler segments, removing the plurality of filler segments from the plurality of mold channels of the die, and arranging the plurality of filler segments in a space in the composite structural component, the space being defined by a radius of the composite structural component, such that the filler segments are in end-to-end contact. The method further comprises curing the plurality of filler segments in the space to fuse the plurality of filler segments.

A system and method for forming a composite part. The apparatus comprises a sleeve that molds a composite material. The sleeve has a first face and a second face. The second face has features to mold the composite material. The first face comprises a first inclined surface having an angle less than about 90 degrees and greater than about 0 degrees.