A thermoplastic prepreg includes a web or mesh of fibers in which the web or mesh of fibers includes chopped fibers. The thermoplastic prepreg also includes a thermoplastic material that fully impregnates the web or mesh of fibers so that the thermoplastic prepreg has a void content of less than 5%. The thermoplastic material is polymers that are formed by in-situ polymerization of monomers or oligomers in which greater than 90% of the monomers or oligomers react to form the thermoplastic material. The thermoplastic prepreg includes between 5 and 95 weight percent of the thermoplastic material and the chopped fibers that form the web or mesh of fibers are un-bonded.

A thermoplastic prepreg includes a mat, web, or fabric of fibers and hollow glass microspheres that are positioned atop the mat, web, or fabric of fibers or dispersed therein. The thermoplastic prepreg also includes a thermoplastic polymer that is fully impregnated through the mat, web, or fabric of fibers and the hollow glass microspheres so that the thermoplastic prepreg has a void content of less than 3% by volume of the thermoplastic prepreg. The thermoplastic material is polymerized monomers and oligomers in which greater than 90% by weight of the monomers or oligomers react to form the thermoplastic material.

In accordance with one embodiment of the present invention, the invention comprises a continuous structural composite preform wet out system and apparatus which takes as an input pre-formed structural composite structures with a structural foam core, passes these structures through a wetting system which may comprise sprayers, brushes, a die or dies, or other wetting means; applies a cure process such as ultraviolet light, heat, curing agent or other cure method, and produces a completed, cured structural composite structure such as a beam or panel for use in any structure as desired by the user. The improved structural composite wet out system of the invention provides run rate, ease of use, structure efficiency and handling advantages over the pultrusion systems of the prior art by achieving higher production rates, the ability to use light cure resins and the ability to produce composite structures of non-uniform cross-section.

A method is disclosed for forming extrudate filament, which consist essentially of fiber, organic binder, and metal and/or ceramic. The extrudate filament can be spooled, or used to form preforms, and/or assemblages of preforms. In further methods, the extrudate filament and/or preforms can be used to fabricate fiber-reinforced metal-matrix or ceramic-matrix or metal and ceramic matrix composite parts, which consist essentially of fiber in a matrix of metal, or ceramic, or metal and ceramic, respectively.

A method for impregnating strands or strips of natural fibers, using the following successive steps: i) the impregnation of the strands or strips by immersion in a bath containing a fine aqueous polymer dispersion; followed by ii) the drying of the strands or strips using a heating system, with the progressive elimination of the water and the gradual melting of the polymer, and the coating of the strands or strips and the molten polymer incorporated into the core of the strands or strips as a binder between the fibers; iii) optionally, the forming of the treated strands or strips into their final shape; and iv) the cooling of the treated strands or strips. The aqueous polymer dispersion comprises at least one semi-crystalline or amorphous polymer and, in the case of an amorphous polymer, has a Tg varying between 50 C. and 175 C.

In accordance with one embodiment of the present invention, the invention comprises a continuous structural composite preform wet out system and method which takes as an input pre-formed structural composite structures with a structural foam core, passes these structures through a wetting system which may comprise sprayers, brushes, a die or dies, or other wetting means; applies a cure process such as ultraviolet light, heat, curing agent or other cure method, and produces a completed, cured structural composite structure such as a beam or panel for use in any structure as desired by the user. The improved structural composite wet out system of the invention provides run rate, ease of use, structure efficiency and handling advantages over the pultrusion systems of the prior art by achieving higher production rates, the ability to use light cure resins and the ability to produce composite structures of non-uniform cross-section.

A method of processing a carbon fiber tow includes the steps of providing a carbon fiber tow made of a plurality of carbon filaments, depositing a sizing composition at spaced-apart sizing sites along a length of the tow, leaving unsized interstitial regions of the tow, and cross-cutting the tow into a plurality of segments. Each segment includes at least a portion of one of the sizing sites and at least a portion of at least one of the unsized regions of the tow, the unsized region including and end portion of the segment.

Provided is a molding material which includes a composite of 1 to 50 wt % of a continuous reinforcing fiber bundle (A) and 0.1 to 20 wt % of a poly(phenylene ether ether ketone) oligomer (B); and 30 to 98.9 wt % of a thermoplastic resin (C) adhering to the composite, wherein the component (B) has a melting point of not higher than 270 C. Also provided are a method for molding the molding material, a method for producing the molding material, and a method for producing a fiber-reinforced composite material. A molded article having high heat resistance and dynamic properties can be easily produced without impairing the economic efficiency and productivity during the process for producing a molding material. In addition, a fiber-reinforced composite material can be produced with more ease and high productivity.

The present invention relates to a method for manufacturing an aerogel sheet. The method for manufacturing the aerogel sheet includes: a step (a) of preparing silica sol; a step (b) of preparing a gelling catalyst; a step (c) of injecting the silica sol, which is prepared in the step (a), to a surface of a blanket to impregnate the silica sol; a step (d) of injecting the gelling catalyst, which is prepared in step (b), to the surface of the blanket, into which the silica sol is impregnated, to gelate the silica sol; and a step (e) of cutting the blanket, in which the silica sol is gelated, to obtain a sheet in which the silica sol is gelated.

Provided are a method for manufacturing a fiber-reinforced resin composite, a fiber-reinforced resin composite manufactured by the manufacturing method, and a molded product, the method comprising the steps of: spinning a fiber filament; coating a surface of the fiber filament by spraying an impregnation resin emulsion onto the spun fiber filament; and forming a fiber strand by bundling the surface-coated fiber filament.