Mats and methods of making the same are described. The mats include a main body defined by a plurality of sidewalls and two exterior surface walls opposing each other, a lip structure extending outwardly from the plurality of sidewalk around a portion of a periphery of the main body, and at least one fiber-reinforcement layer arranged between the two exterior surface walls of the mat. The methods include depositing a first deposition layer of material within a mold, positioning at least one fiber-reinforcement layer on the first deposition layer, depositing a second deposition layer of material within the mold over the at least one fiber-reinforcement layer and the first deposition layer, and treating the first deposition layer, the at least one fiber-reinforcement layer, and the second deposition layer to form a mat.

Composite structures and methods of forming composite structures are provided. The composite structures can include one or more composite structure components. Each composite structure component is formed from a composite panel that includes one or more sheets of material. The sheets of material include a thermoplastic material and a plurality of reinforcing fibers. A composite panel can be formed in three dimensions to form a composite structure component. Multiple composite structure components can be fused to one another to form a composite structure. In addition, each composite structure component and the composite structure formed therefrom can include an aperture. An interior volume can be formed between adjacent composite structure components. Methods for forming a composite structure can include a step of simultaneously molding and fusing composite structure components.

A method is provided in which a fiber-reinforced resin molded article having high dimensional accuracy is obtained by press molding a fiber-reinforced resin. The present invention relates to a method for producing a fiber-reinforced resin molded article by pressing a single prepreg of a fiber-reinforced resin, a plurality of stacked prepregs, or a plurality of stacked prepregs with adhesive resin sheets interposed between the prepregs, said method comprising: a step in which the prepreg is positioned between a heated upper die and a heated lower die; a step in which the upper die is lowered and a load is applied to the prepreg by the upper die and the lower die while further increasing the temperature of the upper die and the lower die; a step in which the upper die and the lower die are maintained at a temperature within a prescribed temperature range while the upper die is positioned at the bottom dead center; a step in which the heating of the upper die and the lower die is reduced or stopped; and a step in which after reducing or stopping the heating, the upper die is raised and the fiber-reinforced resin molded article is extracted.

A composite wheel structure includes a single continuous fiber reinforcement layer extending axially between inner and outer ends of the wheel structure. The single fiber reinforcement layer is impregnated with different matrix materials at different axial portions of the reinforcement layer to account for specific locations where high strength or high temperature performance is needed, with other portions having different matrix materials where low temperature performance and/or low strength is sufficient. The matrix materials may be provided as separate resin films that are applied side-by-side on the single reinforcement layer, or they may be provided on a single resin film. The matrix materials may be applied to the reinforcement layer in a direct coating process. The reinforcement layer may be prepregged with the matrix materials prior to a wheel layup process, or the reinforcement layer and matrix materials may be consolidated by resin film infusion during the wheel layup process.

The present invention generally relates to processes for compression molding a composite article comprising at least one prepreg and at least one transformer film.

A method of manufacturing stiffened structural panel for an aircraft including a main sheet made of composite material with unidirectional fibers, and a stiffening structure secured to the main sheet and made of a composite material comprising a resin and chopped fibers, the stiffening structure including on the one hand a base adhering to one of the two lateral faces of the main sheet, and a network of stiffeners in the form of a grid projecting from the base. The method includes a step of compression molding the stiffening structure from a block formed of a prepolymer reinforced with chopped fibers.

A heating apparatus that heats a thermoplastic resin sheet includes a vertically-movable heating wall that is indirectly heated with a saturated steam of a heat medium and heats the thermoplastic resin sheet above a melting point of the thermoplastic resin by bringing the heating wall into contact with the thermoplastic resin sheet.

A method for forming a crownplate of a golf club head includes the steps of providing a first plurality of composite pre-preg plies, aligning the first plurality of pre-preg plies within a mold cavity in a first configuration in the shape of the crownplate, and heating the plurality of composite pre-preg plies to form the crownplate. The first configuration includes a first thickness area and a second thickness area. The second thickness area is thicker than the first thickness area.

A method of manufacturing includes producing a powder resin comprising a polymer precursor and a thermal initiator, packing a fiber structure with the powder resin, resulting in a resin-packed structure, and heating the resin-packed structure to a curing temperature high enough to melt and cure the resin-packed structure to form a final structure.

The present invention provides: a multilayer sheet which contains a polyolefin resin and carbon fibers, and which is highly competitive in price; and a method for producing this multilayer sheet. A multilayer sheet (100) according to the present invention comprises: a carbon fiber layer (20) which contains a woven fabric of carbon fibers; and polyolefin resin lavers (10) which are in contact with the both surfaces of the carbon fiber layer (20). The carbon fiber layer (20) has a porosity of 10.0% or less. A method for producing this multilayer sheet (100) according to the present invention comprises a process of applying a surface treatment agent to the both surfaces of a woven fabric of carbon fibers, a process of superposing polyolefin resin sheets on the both surfaces of the woven fabric to which the surface treatment agent has been applied, and a process of melting the polyolefin resin by applying a pressure onto the laminate of the polyolefin resin sheets and the woven fabric, while heating the laminate, and subsequently cooling the laminate, thereby obtaining a multilayer sheet.