A stitched multi-axial reinforcement and a method of producing a stitched multi-axial reinforcement. The stitched multi-axial reinforcement (40) may be used in applications where high quality and strength is required. The stitched multi-axial reinforcement includes at least two sets of mono- or bonded multifilaments arranged transverse to one another between reinforcing layers for ensuring good resin flow properties in directions transverse to the direction of the unidirectional rovings (20′, 32′).

A composite panel includes a plurality of segments, wherein each segment includes a plurality of reinforcement plies such as carbon fiber plies. Collimated fiber bands (e.g., carbon fibers) within each reinforcement ply are oriented in a single direction, which can be, for example, 0°, 45°, 90°, and −45°. Each segment can include a stack of reinforcement plies, wherein the collimated fiber bands of each reinforcement ply are oriented in one of these directions. The orientations of the collimated fiber bands that form the reinforcement plies in a stack determine a stiffness of the stack and the segment that includes the stack. The stiffness of each segment is controlled to reduce a stiffness mismatch between adjacent segments that form the composite panel, thereby reducing separation of the segments during use.

A multi-stack material includes a plurality of fiber-reinforced sheets that are laminated. The fiber-reinforced sheets include a first fiber-reinforced sheet in which a first fiber extends in a first direction and a second fiber-reinforced sheet in which a second fiber extends in a second direction that is different from the first direction. The first fiber-reinforced sheet has formed therein a plurality of first slits where the first fiber is cut such that each cut-up segment of the first fiber will have an equal length. The second fiber-reinforced sheet has formed therein a plurality of second slits where the second fiber is cut such that each cut-up segment of the second fiber will have an equal length. The first slits and the second slits are arranged so as to overlap with each other when viewed from the direction of lamination.

Methods and apparatus are provided for the production of thermoplastic composite sheets whose fibers are other than perpendicular to the longitudinal axis of the sheet and which are capable of being slit into sheets, strips and/or tapes of custom widths.

Provided is a method for fabrication of a profile for a spar cap for a wind turbine blade, wherein the profile is fabricated in a pultruding process using one or more strands and/or layers of unidirectional fibres or rovings of unidirectional fibres arranged along a longitudinal direction of the profile and a tool for moulding of the fibres, wherein one or more additional fibres or rovings of additional fibres are introduced in the pultruding process prior to the moulding, wherein the additional fibres are arranged under an angle to the unidirectional fibres, and/or wherein one or more surficial fibres or rovings of surficial fibres are introduced in the pultruding process after the moulding, wherein the surficial fibres are arranged on the outer surface of the moulded profile.

This specification discloses an article of manufacture. The article of manufacture has at least one structural blank and at least one guide. The structural blank has a plurality of oriented fiber plies in a thermoplastic matrix. The guide has a plurality of random dispersed fibers in a thermoplastic matrix. The guide is affixed to the structural blank by injection molding and over molding the guide onto the structural blank. The article of manufacture can take a number of forms for use in industries such as aircraft, automobiles, motorcycles, bicycles, trains or watercraft.

A reinforced substrate is provided for use in molding a composite material. The reinforced substrate has a reinforcing layer having reinforcing fibers extending in a fiber direction that is aligned in a single direction and auxiliary fibers laminated on only one surface of the reinforcing layer so as to extend in only one direction that intersects with the fiber direction. The auxiliary fibers are joined to the reinforcing fibers to hold the reinforcing layer. The auxiliary fibers have a higher tensile elongation at break than do the reinforcing fibers. The reinforcing layer is arranged with fiber bundles of large tows being aligned in an unopened state. The large tows have a higher fiber count of the reinforcing fibers than does a regular tow.

An aircraft body section comprises a first layer of composite material, a first group of conductive traces, a second layer of composite material, and a first group of conductive connectors. The first layer of composite material has an upper surface and a lower surface, with the lower surface forming an exterior surface of a body of the aircraft. The first group of conductive traces are formed on the upper surface of the first layer of composite material. The second layer of composite material is positioned on the first layer of composite material and has an upper surface and a lower surface, with the upper surface forming an interior surface of a body of the aircraft. The first group of conductive connectors is formed on the upper surface of the second layer of composite material and is configured to provide electrical connection from external conductors to the conductive traces.

An FRP continuous molding apparatus continuously molds an FRP from a layered sheet that includes prepreg sheets layered over each other. The prepreg sheets each include thermoplastic resin and reinforcement fibers, and differ from each other in fiber orientation. The FRP continuous molding apparatus includes: sheet feeding devices continuously feeding the layered sheets in a feeding direction; a layering device layering, over each other, the layered sheets fed from the sheet feeding devices, and thereby forming a sheet layered body; and a shaping mechanism molding the sheet layered body into an FRP while the sheet layered body is being transferred in the feeding direction. The FRP has a cross section that is a target shape. The sheet layered body includes the reinforcement fibers whose fiber orientation is the feeding direction.

A prepreg sheet includes a plurality of prepreg tapes each of which overlaps with a corresponding adjacent prepreg tape for a suitable overlapping length. The plurality of prepreg tapes each contain a reinforcing fiber bundle that is impregnated with a thermosetting resin composition. According to a method for manufacturing a preform, for example, a primary premolded article is manufactured by preforming an intermediate base material containing a reinforcing fiber base material and a matrix resin composition, and a secondary premolded article is manufactured by preforming the primary premolded article on which the intermediate base material is further placed.