A method for manufacturing an outer skin of a rotor blade includes forming an outer skin layer of the outer skin from a first combination of at least one of one or more resins or fiber materials. The method also includes forming an inner skin layer of the outer skin from a second combination of at least one of one or more resins or fiber materials. More specifically, the first and second combinations are different. Further, the method includes arranging the outer and inner skin layers together in a stacked configuration. In addition, the method includes joining the outer and inner skin layers together to form the outer skin.

A hybrid reinforcement material (18) is disclosed that includes a plurality of reinforcement fibers (12) and a plurality of carbon fibers (14) comingled with the reinforcement fibers (12). The reinforcement fibers (12) are selected from natural fibers, organic fibers, and inorganic fibers and form a single hybrid assembled roving with the carbon fibers (14). The carbon fibers (14) are post-coated with a compatibilizer. The hybrid assembled roving (18) may be formed using a hybrid of glass and carbon fibers.

A die assembly for forming a composite gap filler, including a first die having a first portion which extends along a first central axis of the first die and has a first curved surface which has a radius which changes as the first curved surface extends about the first central axis. A second die a second portion which extends along a second central axis of the second die and has a second curved surface which has a radius which changes as the second curved surface extends about the second central axis. A third die defines a third wall member which extends about the third die and which changes in width dimension wherein with the first die abutting the second die and with the third wall member abutting the first and second dies, a closed gap is formed.

A method for making a conductive pre-impregnated composite sheet includes the steps of joining a nanomaterial composite sheet, a fiber-reinforcing sheet and a resin system to form a combined sheet, heating the combined sheet, compacting the combined sheet, and cooling the combined sheet to form conductive pre-impregnated composite sheet including the fiber-reinforcing sheet, and the nanomaterial composite sheet coupled to the fiber-reinforcing sheet, wherein the fiber-reinforcing sheet and the nanomaterial composite sheet are embedded in the resin system.

A method for impregnating a fibrous material with a curable resin to form a prepreg is disclosed. The method includes conveying a web material through at least one moving pressure nip formed between a moving pressure roller and a moving supporting surface, wherein the moving pressure roller and the moving supporting surface travel at different velocities relative to each other resulting in a relative velocity between the web material and the pressure nip. The at least one moving pressure nip travels in the same direction as the web material while applying sufficient pressure to compress the web material and to affect impregnation of the fibrous material with the curable resin. Also disclosed is a system for implementing the disclosed impregnation method.

According to one implementation, a composite material shaping device includes three rollers and an angle adjusting structure. The three rollers apply pressures on a laminated body of prepregs, from different directions. The prepregs are laminated in a bar shape. The angle adjusting structure continuously changes an angle of a rotating axis of at least one roller out of the three rollers. Further, according to one implementation, a composite material shaping method includes applying pressures on a laminated body of prepregs laminated in a bar shape, from different directions, using three rollers; and producing a shaped laminated body of the prepregs by continuously changing an angle of a rotating axis of at least one roller out of the three rollers.

A fiber composite laying method for producing a fiber composite scrim for forming a fiber composite component. The method includes supplying a reinforcement fiber band to a laying head, laying and compacting the supplied reinforcement fiber band on a laying surface at an average compaction pressure by a compaction roller, and detecting a local compaction pressure on the laid reinforcement fiber band by pressure sensors on the compaction roller.

A fiber composite laying device for producing a fiber composite scrim for forming a fiber composite component has a laying head which is designed or configured to continuously supply a reinforcement fiber band, a compaction roller which is designed or configured to receive the supplied reinforcement fiber band, lay the band on a laying surface and press the band onto the laying surface at an average compaction pressure, and pressure sensors which are arranged on the compaction roller and are designed or configured to detect a local compaction pressure on the laid reinforcement fiber band.

Provided are a carbon fibre thermoplastic resin prepreg which is a carbon fibre prepreg obtained by impregnating a PAN-based carbon fibre in which the average fibre fineness of a single fibre is 1.0 dtex to 2.4 dtex with a thermoplastic resin, wherein the thermoplastic resin satisfies 20<(FM/FS)<40 (where FM: flexural modulus (MPa) of a resin sheet comprising only the thermoplastic resin, and FS: flexural strength (MPa) of the resin sheet), a method for manufacturing the same, and a carbon fibre composite material employing the carbon fibre prepreg.

The invention relates to a process for the production of saturated fiber structures. The process includes (a) introduction of a fiber structure onto a conveyor belt; (b) application of a solution including monomer and optionally including activator, and optionally including catalyst in at least one line to the fiber structure; (c) passage of the fiber structure with the solution through at least one roll pair in which pressure is exerted on the fiber structure; and (d) cooling of the saturated fiber structure, so that the monomer solidifies.