Systems and methods are provided for applying lengthwise curvature to composite parts. One embodiment is a method that includes fabricating a preform for a curved pultruded gap filler by continuously: heating fiber reinforced material to a sticking point temperature for a constituent material within the fiber reinforced material, and feeding the fiber reinforced material through a die that exhibits a curvature through which the fiber reinforced material travels while the fiber reinforced material is heated to the sticking point temperature, the die forming the fiber reinforced material into a preform for a gap filler. Fabricating the curved pultruded preform further includes varying path lengths of fibers within the preform as the preform passes through the die, and pulling the preform out of the die.

Provided herein are composite materials comprising at least 70 wt. % thermally consolidated recovered paper and plastic fragments and less than 5,000 ng water-soluble endotoxin per gram of composite materials, as well as methods of preparing said composite materials and methods of sanitizing recovered waste materials.

A die or die assembly for forming a bundle of fibres into a rod or tube comprises a body (84) defining a passage 86) for conducting the bundle fibres through the die from an inlet to an outlet, a constriction (91) in the passage having an entrance shaped to form the fibres of the bundle into a desired configuration as the bundle passes through the die, and one or more conduits (92) through which a treatment fluid e.g. steam, for curing the bundle of fibres may be introduced into the passage, and wherein at last one conduit is arranged to discharge fluid in the immediate vicinity of the entrance to the constriction to facilitate passage of the fibres through the die and reduce the risk of blockage.

A forming process for composite parts comprising pultruding a resin and fiber material through a shortened pultrusion die, exposing the pultruded resin and fiber material to an induction heating coil aligned to be in-line with the pultrusion die to cure the resin and fiber material, wherein one or more of the resin and/or fiber material include a metallic component to facilitate cure via the induction heating coil.

Provided herein are composite materials comprising at least 70 wt. % thermally consolidated recovered paper and plastic fragments and less than 5,000 ng water-soluble endotoxin per gram of composite materials, as well as methods of preparing said composite materials and methods of sanitizing recovered waste materials.

According to one implementation, a preform shaping method for producing a preform having a web, a flange, and a chamfered portion includes: pressing a first portion of a laminated body of fiber sheets by sandwiching the first portion between a first mold and a second mold; and pressing a second portion of the laminated body of the fiber sheets after pressing the first portion. The first portion corresponds to the web. The second portion corresponds to the flange. The first mold fits a surface in one side of the web, an inner surface of the chamfered portion and a surface in one side of the flange. The second mold fits a surface in the other side of the web. The second portion is pressed by sandwiching the second portion between the first mold and a third mold.

Provided herein are composite materials comprising at least 70 wt. % thermally consolidated recovered paper and plastic fragments and less than 5,000 ng water-soluble endotoxin per gram of composite materials, as well as methods of preparing said composite materials and methods of sanitizing recovered waste materials.

Disclosed herein a method for making a unidirectional continuous fiber-reinforced resin composite material. A resin plasticized and molten by an extruder is transported to a coating guide roller through a die head, and a hot-melt resin film layer with uniform thickness is formed on a roller surface of the coating guide roller. Simultaneously, the coating guide roller guides the hot-melt resin to continuously and uniformly coat on a row of flattened unidirectional continuous fibers along the roller surface of the coating guide roller. Subsequently, the coated flattened unidirectional continuous fibers pass through an open dip-coating roller device to effectively combine with the hot-melt resin to obtain a composite material of the hot-melt resin and fibers, which passes through a cooling and forming device to a winder under a driving force of a main traction to obtain the unidirectional continuous fiber-reinforced resin composite material.

A machine and a method produce strips from a fiber-reinforced plastics composite material. The machine includes a housing through which fibers pass and in which profiled bars are fixedly or rotatably mounted, which are oriented perpendicularly to the passing direction of the fibers and by which forces can be applied alternately to the top and bottom of the fibers and to their coating with a plastics material in order to impregnate the fibers and to consolidate the plastics material between the fibers. The ratio of the average total contact length of all the profiled bars used in the impregnation in millimeters to the number of profiled bars is between 2:1 and 1:400, preferably between 1 and 1:200 and particularly preferably between 1:10 and 1:100.

The invention relates to a process for the production of a tape comprising a plurality of impregnated continuous multifilament strands and a polymer sheath which intimately surrounds the plurality of impregnated continuous multifilament strands, wherein each of the plurality of impregnated multifilament strands extends in the longitudinal direction, wherein each of the plurality of impregnated continuous multifilament strands comprises at least one continuous glass multifilament strand, wherein the at least one continuous glass multifilament strand is impregnated with an impregnating agent, wherein the process comprising the steps of a) unwinding from a package the continuous glass multifilament strands, b) applying the impregnating agent to the continuous glass multifilament strands to form the plurality of impregnated continuous multifilament strands, c) placing the plurality of impregnated continuous multifilament strands in parallel alignment in the longitudinal direction and d) applying a sheath of a thermoplastic polymer composition around the plurality of impregnated continuous multifilament strands of step c) to form the tape, wherein steps c) and d) are performed in a die having a guiding means arranged for placing the plurality of impregnated continuous multifilament strands in parallel alignment in the longitudinal direction, wherein the plurality of impregnated continuous multifilament strands pass through a melt of the thermoplastic polymer composition inside of the die downstream of the guiding means.