The composite pultruded products either in I profile or Plate profile of higher cross sectional area where said products consisting essentially synthetic polyester felts as core impregnated with a resin system comprises of at least one resin, curing system comprising a curing agent and an accelerator, a filler, a thinner, pigment or any other additives; encapsulated between bi-directionally and/or uni-directionally oriented synthetic fabric selected from polyester, carbon, aramid, glass, basalt and mixtures thereof impregnated with said resin system are provided. In another composite pultruded products either in I profile or Plate profile of higher cross sectional area where said products consisting of plank of short fibers bagasse premixed with the said resin system as core is enclosed between the synthetic polyester felts impregnated with the resin system which is further enclosed between bi-directionally and/or uni-directionally oriented synthetic fabric selected from polyester, carbon, aramid, glass, basalt and mixtures thereof impregnated with the resin system. The system and method for the preparation of said composite pultruded products are also illustrated herein. These products lead to a significant reduction in weight and reduction in density with higher stiffness and bending strength. The present composite products are encapsulated by fabrics in the peripheral area bringing more integrity uniformity of synthetic polyester felt materials. This leads to a significant cost reduction without sacrificing much tensile strength.

Provided are a device and a method capable of suitable cooling of a fiber bundle without hindering nozzle maintenance work or preparation work before the start of manufacturing. The provided device includes a nozzle which allows the fiber bundle impregnated with thermoplastic resin to pass therethrough while forming the fiber bundle into a tape shape, a cooling roller for cooling the fiber bundle, and a supporting device. The supporting device supports the cooling roller rotatably so as to allow the cooling roller to be moved between a cooling position at which an outer periphery surface of the cooling roller makes contact with the fiber bundle having passed through the nozzle and a retraction position away from the nozzle beyond the cooling portion.

An alternating pressure melt impregnation device and a melt impregnation method, including having a resin melt squirted from each resin melt runner on an upper die and a lower die of a melt injection area, and thus the squirted resin melt is enable to be squirted directly on an upper surface and a lower surface of a continuous fiber bundle which is entering into an impregnation chamber. Impregnation and infiltration for both surfaces of the continuous fiber bundle are primarily completed by a squirted pressure. The resin melt inside the impregnation chamber flows to a decompression chambers at both sides of the impregnation chamber. When the resin melt flows to a throttle plate, a re-impregnation for the continuous fiber bundle is realized. Then the pressure is decreased and a section of the resin melt is enlarged and a radial flow is generated due to the Barus effect.

A pultrusion process for making a strip for an elongate reinforcing structure of a wind turbine blade, the process comprising drawing fibres (42) and resin through a pultrusion die (40) in a process direction to form a strip (102); and applying an infusion-promoting layer (110) to a surface of the strip down-stream from the die in the process direction. A pultrusion apparatus is also disclosed.

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.

Continuous manufacturing systems and methods for fiber components are described. The continuous manufacturing systems may include core preparation, fiber weaving, pressure application, fiber curing, cooling, and post-processing subsystems. For example, fiber components having varying shapes, weaving parameters, and/or structural properties may be continuously formed. In addition, various additional fibers having additional functions or characteristics may be continuously woven together in the fiber components. Further, the pressure application, curing, and/or cooling subsystems may utilize various outer dies that are cycled through and between the subsystems.

A method for manufacturing a part for a wind turbine blade, and in particular a part of a shear web for a wind turbine blade, is described. The method comprises pultruding the part, wherein an in-line shaping of the part is performed, to provide a part having a cross-sectional profile which varies in the longitudinal length of the part. Providing a shear web having a portion which varies in cross-sectional profile results in production of a wind turbine blade part which can be accurately controlled to have precise geometrical profile corresponding to a desired blade profile, with minimal waste of 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.

Methods for forming composite articles include providing a non-crimp fabric (NCF) comprising a plurality of fiber plies maintained in a layup by stitching, wherein the stitching exhibits a lower structural tolerance to heat and/or UV light relative to the fiber plies, selectively degrading the stitching in one or more areas using heat or UV light, draping the NCF on a contoured article, applying a polymer matrix material to the draped NCF, and curing the polymer matrix material to form a contoured composite article. The stitching can be degraded in regions of the NCF which, when draped on the contoured article, correspond to topological features of the contoured article. Degrading the stitching can comprise breaking the stitching. The fiber plies can comprise carbon fibers, glass fibers, and/or basalt fibers. The contoured article can be tooling and/or an automotive component. The NCF can be a bi-axial NCF.

The invention aims to provide a tape-shaped prepreg including unidirectionally oriented reinforcing fibers and a thermoplastic resin composition and being high in handleability during molding and high in adhesiveness to other members. The tape-shaped prepreg includes unidirectionally oriented reinforcing fibers and a thermoplastic resin composition and has an arithmetic average roughness (Ra) of 0.1 to 10 ?m in a direction perpendicular to the orientation direction of the reinforcing fibers, as measured according to JIS B 0601: 2013, and a warpage rate of 5% or less as determined by the procedure specified in (i) to (iii) below: (i) place a test piece of the above tape-shaped prepreg having a length of 100 mm in the fiber orientation direction on a plane in such manner that the end portions curl upward, (ii) measure the vertical distance from the highest position at the right end of the curled tape to the plane, which is denoted by a, and the vertical distance from the highest position at the left end to the plane, which is denoted by b, and calculate the arithmetic average of a and b, which is defined as the warpage distance, and (iii) calculate the warpage rate by the following equation: warpage rate (%)=warpage distance (mm)/100 (mm)?100.