A method for making a carbon carbon, carbon ceramic matrix, or carbon silica composite, comprising melt processing a resin comprising a polyaryletherketone (PAEK) and at least one reinforcing additive to make a precursor part, pyrolyzing the precursor part to make a pyrolyzed part, infusing a liquid second resin into the pyrolyzed part to make an infused part, and pyrolyzing the infused part. Other methods comprise processing aligned reinforcing additives and a resin comprising a PAEK to make an aligned reinforcing additives PAEK, aligned 1-2 dimensional flake material, or aligned 1-2 dimensional platelet material, to create a fabric, prepreg or tape comprising the aligned reinforcing additives and impregnated PAEK. Other methods comprise impregnating continuous fiber tape or fabric with a resin comprising PAEK and at least one reinforcing additive or co-weaving a continuous fiber or fabric with a PAEK fiber comprising PAEK and at least one reinforcing additive.

A process for forming a mat containing a fiber filler including providing one or more sources of extended length fiber; feeding the one or more sources of extended length fiber simultaneously to an automated cutting machine to produce chopped tow fibers; separating the chopped fiber tow into individual chopped fibers that form a fiber filler; coating the fiber filler with a binder; depositing the fiber filler on a first sheet of thermoplastic; covering the fiber filler with a second sheet of thermoplastic to form a stack; and moving the stack to a treatment chamber to form a fiber mat.

Provided herein is a method for aligning discontinuous fibres comprising: providing a stream of discontinuous fibres in a dispersion medium; applying a shear stress to the dispersion medium to align at least a portion of the discontinuous fibres; and disposing the at least a portion of the aligned discontinuous fibres on a substrate thereby providing a layer of substantially aligned discontinuous fibres. Also provided are discontinuous fibres aligned by such method and a composite material formed from the aligned discontinuous fibres.

A composite component (16) for a vehicle (10) includes a laminate (18) made from a composite material, a first pad-up area (22) applied to the laminate (18), where the first pad-up area (22) includes a plurality of first tows laid next to one another in a side-by-side arrangement and where the first pad-up area (22) defines a first fiber orientation, and a second pad-up area (24), where the second pad-up area (24) includes a plurality of second tows laid next to one another in a side-by-side arrangement and where the second pad-up area (24) defines a second fiber orientation that differs by a predetermined angle from the first fiber orientation. The first pad-up area (22) and the second pad-up area (22) intersect at an intersecting area and together form a first pad-up ply on the laminate (18).

A composite component (16) for a vehicle (10) includes a laminate (18) made from a composite material, a first pad-up area (22) applied to the laminate (18), where the first pad-up area (22) includes a plurality of first tows laid next to one another in a side-by-side arrangement and where the first pad-up area (22) defines a first fiber orientation, and a second pad-up area (24), where the second pad-up area (24) includes a plurality of second tows laid next to one another in a side-by-side arrangement and where the second pad-up area (24) defines a second fiber orientation that differs by a predetermined angle from the first fiber orientation. The first pad-up area (22) and the second pad-up area (22) intersect at an intersecting area and together form a first pad-up ply on the laminate (18).

Provided are a low dielectric loss non-woven fabric, a preparation method thereof and use thereof. The low dielectric loss non-woven fabric is composed of an inorganic fiber and a binder, and the binder is any one or a combination of at least two of a fluorine-containing resin emulsion, a polyolefin emulsion, a polyphenylene ether resin or a cyanate ester resin. The non-woven fabric of the present application has good dielectric properties and obvious strengthening effect, and can meet various performance requirements for copper clad laminate materials in the field of high-frequency communication.

Provided are a low dielectric loss non-woven fabric, a preparation method thereof and use thereof. The low dielectric loss non-woven fabric is composed of an inorganic fiber and a binder, and the binder is any one or a combination of at least two of a fluorine-containing resin emulsion, a polyolefin emulsion, a polyphenylene ether resin or a cyanate ester resin. The non-woven fabric of the present application has good dielectric properties and obvious strengthening effect, and can meet various performance requirements for copper clad laminate materials in the field of high-frequency communication.

There is provided a method that includes directing one or more infrared cameras at a compaction roller of a composite laying head of a composite layup machine. The one or more infrared cameras are mounted aft of the compaction roller. The method includes applying heat to a substrate by a heater. The heater is mounted forward of the compaction roller. The method further includes using the one or more infrared cameras, to obtain one or more infrared images of the compaction roller, during laying down of one or more composite tows of a composite layup onto the substrate by the compaction roller. The method further includes identifying, based on the one or more infrared images, one or more temperature profiles of the compaction roller, and analyzing identified temperature profiles, to determine one or more of, a layup quality of the composite layup, and a heat history of the composite layup.

In an embodiment, an energy-absorbing device can comprise: a polymer reinforcement structure, wherein the polymer reinforcement structure comprises a polymer matrix and chopped fibers; and a shell comprising 2 walls extending from a back and forming a shell channel, wherein the shell comprises continuous fibers and a resin matrix; wherein the polymer reinforcement structure is located in the shell channel.

Present invention is related to an extrusion equipment for processing a fibre composite. The extrusion equipment comprises a decompression and a melt tank arranged and operated vertically along with the direction of gravity. The melt tank comprises a melt tank impregnation section and a melt tank control section with a melt tank cavity as a channel condition defined within. The channel has its inner diameter or passage gradually decreased from top to bottom. The extrusion equipment provided by the present invention is configured in the direction of gravity for processing the melted thermoplastic resin and the fibre vertically for avoiding fibre fracture or breakage and improving the quality of the final products. As the melted plastic is processed vertically along with the gravity, the melted plastic could transfer or pass through the channel quickly without resulting decomposition due to the high heat and the long retention time in the cavity.