A form for a thin reinforced composite material includes a plurality of separate linear fiber strips, each having a rectangular cross section composed of reinforcement fibers. The linear fiber strips laid out in a two-dimensional base layer defining a shape of the form. A first successive layer formed with the plurality of separate linear fiber strips contacting the base layer, the linear fiber strips laid out in the first successive layer interspersed from the separate linear fiber strips in the two-dimensional base layer. A method of forming the form includes arranging the plurality of separate linear fiber strips on a substrate and tacking the plurality of separate linear fiber strips to the substrate with a plurality of stitches. A method of forming a unitary reinforced composite component from the form is further provided. The resulting component having high strength and light weight and being efficient to manufacture.

A form for a thin reinforced composite material includes a plurality of separate linear fiber strips, each having a rectangular cross section composed of reinforcement fibers. The linear fiber strips laid out in a two-dimensional base layer defining a shape of the form. A first successive layer formed with the plurality of separate linear fiber strips contacting the base layer, the linear fiber strips laid out in the first successive layer interspersed from the separate linear fiber strips in the two-dimensional base layer. A method of forming the form includes arranging the plurality of separate linear fiber strips on a substrate and tacking the plurality of separate linear fiber strips to the substrate with a plurality of stitches. A method of forming a unitary reinforced composite component from the form is further provided. The resulting component having high strength and light weight and being efficient to manufacture.

A manufacturing method of a halogen-free flame-retardant thermoplastic braided fiber reinforced polymer composite board, comprising steps of: preparing a recycled material containing a halogen-free flame-retardant thermoplastic braided fiber reinforced polymer composite; adding a polymer base material to the recycled material to form a core layer material and extruding the core layer material with a low shear extruder; hot pressing the core layer material by rollers to obtain a recycled fiber core layer; preparing a reinforcement layer containing a fiber material or a fabric with pores; and stacking and hot pressing the recycled fiber core layer and the reinforcement layer.

A molding process for the production of a cover wall section for a cover in which the cover wall section has at least one multi-layer fabric that has a reinforcement and, at least on one side, preferably on both sides, a polymer coating, has the following process steps: Provision of at least one multi-layer fabric; draping of the at least one fabric over a molding surface of a mold and stretching of the at least one fabric across the molding surface by at least one tension element; and curing of the at least one fabric and/or the at least one tension element in such a way that the cover wall section is fixed in its shape.

A three-dimensional fibrous preform of a fan blade includes a blade root and a blade airfoil between the blade root and a free end of the preform. The airfoil has an area with two skins and a longitudinal stiffener between the skins and, in a transverse plane, transverse yarns of the skins woven in pairs in the first and in the second skin either side of the stiffener, the yarns of a first pair of the first skin are separated into two unit yarns at the stiffener, the unit yarns being woven separately with longitudinal yarns, the yarns of a second pair of the second skin are separated into two unit yarns at the stiffener, the yarns being woven separately with longitudinal yarns, and a yarn of each pair cross over each other twice in the stiffener.

A three-dimensional fibrous preform of a fan blade includes a blade root and a blade airfoil between the blade root and a free end of the preform. The airfoil has an area with two skins and a longitudinal stiffener between the skins and, in a transverse plane, transverse yarns of the skins woven in pairs in the first and in the second skin either side of the stiffener, the yarns of a first pair of the first skin are separated into two unit yarns at the stiffener, the unit yarns being woven separately with longitudinal yarns, the yarns of a second pair of the second skin are separated into two unit yarns at the stiffener, the yarns being woven separately with longitudinal yarns, and a yarn of each pair cross over each other twice in the stiffener.

A process for manufacturing a blade made of composite material for a turbomachine is provided. The blade includes an airfoil having a pressure side and a suction side which extend from a leading edge to a trailing edge of the airfoil. The blade further includes a metal sheath that extends along the leading edge of the airfoil. The process includes the steps of: a) placing a preform, made by three-dimensionally weaving fibers, in a mold, a polymerizable adhesive being inserted between the sheath and the edge of the preform; and b) injecting polymerizable resin into the mold to impregnate the preform so as to form the airfoil after solidifying, wherein the resin is injected within a time interval during which the adhesive reaches a freezing point.

A process for manufacturing a blade made of composite material for a turbomachine is provided. The blade includes an airfoil having a pressure side and a suction side which extend from a leading edge to a trailing edge of the airfoil. The blade further includes a metal sheath that extends along the leading edge of the airfoil. The process includes the steps of: a) placing a preform, made by three-dimensionally weaving fibers, in a mold, a polymerizable adhesive being inserted between the sheath and the edge of the preform; and b) injecting polymerizable resin into the mold to impregnate the preform so as to form the airfoil after solidifying, wherein the resin is injected within a time interval during which the adhesive reaches a freezing point.

The invention relates to an impregnated yarn, a ribbed thin-walled composite product comprising such an impregnated yarn, and a method of making them. Such an impregnated yarn (10d; 10e) comprises at least two continuous strands (10a; 10b) comprising plant fibers (11), said strands (10a; 10b) being impregnated with thermoplastic material (12a) in at least 60% of their volume, each of said strands (10a; 10b) being individually twisted and all of said strands (10a; 10b) also being twisted in a configuration (10d) held by the thermoplastic material (12a).

The invention relates to an impregnated yarn, a ribbed thin-walled composite product comprising such an impregnated yarn, and a method of making them. Such an impregnated yarn (10d; 10e) comprises at least two continuous strands (10a; 10b) comprising plant fibers (11), said strands (10a; 10b) being impregnated with thermoplastic material (12a) in at least 60% of their volume, each of said strands (10a; 10b) being individually twisted and all of said strands (10a; 10b) also being twisted in a configuration (10d) held by the thermoplastic material (12a).