Ballistic resistant composite materials having high positive buoyancy in water are provided. More particularly, provided are foam-free, buoyant composite materials fabricated using dry processing techniques. The materials comprise fibrous plies that are partially coated with a particulate binder that is thermopressed to transform a portion of the binder into raised, discontinuous patches bonded to fiber/tape surfaces, while another portion of the particulate binder remains on the fibers/tapes as unmelted particles. The presence of the unmelted binder particles maintains empty spaces within the composite materials which increases the positive buoyancy of the composites in water.

There is provided a process for preparing a prepreg (31) comprising reinforcement fibre (13) impregnated with a thermosetting resin matrix (20), said process comprising: a) providing a layer (24) of reinforcement fibre (13); b) applying a layer (24) of a first thermosetting resin matrix (20) to the first surface (15) of the layer (24) of reinforcement fibre (13) and bringing the first surface (15) of the layer (24) of reinforcement fibre (13) into contact with the support surface (5) of a first continuous belt (3), so that the layer (24) of first thermosetting resin matrix (20) is positioned between, and in contact with, the first surface (15) of the layer (24) of reinforcement fibre (13) and the support surface (5) of the first continuous belt (3); c) heating the layer (24) of first thermosetting resin matrix (20) applied to the first surface (15) of the layer (24) of reinforcement fibre (13) in contact with the support surface (5) of the first continuous belt (3); d) bringing the second surface (17) of the layer (24) of reinforcement fibre (13) into contact with the support surface 9) of a second continuous belt (7); e) heating the layer (24) of first thermosetting resin matrix (20) and the layer (24) of reinforcement fibre (13) between the support surfaces of the first and second continuous belts (3, 7) so that the first thermosetting resin matrix (20) impregnates the layer (24) of reinforcement fibre (13); f) cooling the layer (24) of reinforcement fibre (13) impregnated with the first thermosetting resin matrix (20) between the support surfaces of the first and second continuous belts (3, 7); and g) removing the layer (24) of reinforcement fibre (13) impregnated with the first thermosetting resin matrix (20) from the support surfaces of the first and second continuous belts (3, 7).

A sheetlike composite material including at least one layer A of a nonwoven thermoplastic fiber web or a thermoplastic film, and at least two unidirectional oriented-fiber layers B and B, the layers B and B having a bidirectional fiber orientation. The layers are not only needled but also stitched to one another.

A method of manufacturing an impregnated fibrous material including a fibrous material made of continuous fibers and at least one thermoplastic polymer matrix, the method including pre-impregnating the fibrous material while it is in the form of a roving or several parallel rovings with the thermoplastic material and heating the thermoplastic matrix for melting, or maintaining in the molten state, the thermoplastic polymer after pre-impregnation, the at least one heating step being carried out by means of at least one heat-conducting spreading part (E) and at least one heating system, with the exception of a heated calendar, the roving or the rovings being in contact with part or all of the surface of the at least one spreading part (E) and partially or wholly passing over the surface of the at least one spreading part (E) at the level of the heating system.

The present invention provides a fiber-reinforced resin intermediate material, including not only a thermoplastic resin but also a thermosetting resin, in which defects such as voids are difficult to be generated and which is excellent in shaping ability; and a method for manufacturing the same. The fiber-reinforced resin intermediate material according to the present invention is a fiber-reinforced resin intermediate material formed by attaching a resin to an outer surface part of a reinforcing fiber substrate formed of reinforcing fibers subjected to opening and heating the resin to a temperature equal to or higher than the melting point of the resin to impregnate the reinforcing fiber substrate with the resin, wherein the reinforcing fiber substrate has void space that is opened on an outer surface thereof and the resin is in a semi-impregnated state.

A panel for forming a floor covering, where this panel includes a substrate including at least a layer of thermoplastic material, where the panel, above the layer, comprises at least also a printed decor and a translucent or transparent wear layer. The layer also includes at least individual fibers having a length greater than 1 millimeter, where the individual fibers are loose and freely distributed within the layer of thermoplastic material.

A fiber composite laminate having one or more fiber layers, comprising a first laminate region and a second laminate region. In the first laminate region, the fiber layers of the fiber composite laminate are impregnated with a thermoplastic elastomer material. In the second laminate region, fiber layers of a first lamina of the fiber composite laminate are impregnated with the thermoplastic elastomer matrix, and fiber layers of at least one second lamina of the fiber composite laminate that is positioned on top of the first lamina are impregnated with a thermosetting polymer matrix.

Floor panel for forming a floor covering, where the floor panel includes a carrier on the basis of a thermoplastic material and a top layer provided on the carrier. The thermoplastic material is free from plasticizers or includes a plasticizer in an amount up to maximum 20 phr, where the thermoplastic material is foamed or expanded, and where the carrier is provided with a reinforcement layer.

A method for manufacturing panels with at least a substrate and a top layer. The method having the steps of providing a granulate having thermoplastic material and having an average particle size of less than 1 millimeter, forming a substrate layer by strewing the granulate, consolidating the layer between the belts of a continuous press device, and providing the top layer on the substrate.

Ballistic resistant composite materials having high positive buoyancy in water are provided. More particularly, provided are foam-free, buoyant composite materials fabricated using dry processing techniques. The materials comprise fibrous plies that are partially coated with a particulate binder that is thermopressed to transform a portion of the binder into raised, discontinuous patches bonded to fiber/tape surfaces, while another portion of the particulate binder remains on the fibers/tapes as unmelted particles. The presence of the unmelted binder particles maintains empty spaces within the composite materials which increases the positive buoyancy of the composites in water.