The present invention provides a fiber-reinforced-resin composite molded article including: a rigid layer that is formed of a fiber-reinforced-resin material for a rigid layer; a shaping layer that is formed, at least on one side of the rigid layer, of a shaping-layer compound composed of a thermosetting resin and fibers that are shorter than fibers contained in the fiber-reinforced-resin material for a rigid layer; and a cured resin being formed of a liquid-state resin that is deposited on the surface of the shaping layer. The fiber-reinforced-resin composite molded article has a structure in which the fiber-reinforced-resin material for a rigid layer, the shaping-layer compound, and the liquid-state resin are cured under heat and pressure in a layered state.

The disclosed composite structure provides a reinforced thermoplastic polymer composite part with a high-quality surface finish. This may be used as a vehicle part or body panel, such as an interior vehicle part or exterior body panel. Additionally, the surface finish may be coloured, such that the surface does not need to be painted or wrapped to achieve a desired surface colour, and the surface may protect inner layers from UV radiation, either by virtue of the material of the surface itself, or the incorporation of a UV-absorbing additive. Specifically, the disclosed composite structure comprises a structural layer comprising reinforcing fibres, such as glass or carbon fibres, and a thermoplastic body polymer. The structure further comprises a surface layer providing a surface finish to the composite structure, the surface layer comprising a thermoplastic surface polymer substantially free from reinforcing fibres.

A method of manufacturing a high-pressure composite pressure vessel for high-pressure being at or above 70 bar (1000 PSI or 7 MPa) includes providing an expandable core vessel defining a hoop section between end domes. An aligned discontinuous fiber composite material is wrapped over the expandable core vessel aligning with a plurality of load paths present in the expandable core vessel being over the hoop section and end domes. The aligned discontinuous fiber composite material has fibers in a prepreg tape that are at least 5 mm in length to 100 mm in length or less. Next, a continuous fiber-reinforced composite is wrapped over the aligned discontinuous fiber-reinforced composite along the hoop section and not wrapped along the end domes. The expandable core vessel may be pressurized and heated to consolidate the composite overwrap. Finally, the vessel is cooled under pressure resulting in the high-pressure composite pressure vessel.

The present invention relates to methods for forming a composite product having a patterned surface. A substrate including a porous structure (136), a sheet-form material (134) and a patterned sheet (131) are pressed together to form the composite product. In preferred examples, the patterned sheet is permeable to curable material in the sheet-form material.

The present invention relates to multi-layered composite structures and to methods for the preparation thereof. The present multi-layered composite structures are light weight and capable of high load bearing making the present multi-layered composite structures especially suitable to be used as load bearing structures in, for example, automotive. Specifically, the present invention relates to methods comprising the steps of a) providing a mould for said multi-layered composite structure; b) layering said mould with two or more layers forming the outer surface of said multi-layered composite; c) filling said layered mould with a mixture comprised of non-expanded heat-expandable microspheres and closing said mould; and d) subjecting said closed mould to a temperature of 80° C. to 140° C. during 1 to 230 minutes thereby providing a relative pressure in said closed mould of 0.1 to 20 bar through expansion of said heat-expandable microspheres thereby forming a multi-layered composite structure in said mould with a foam enforced inner core and a multi-layered outer surface; and e) separating the multi-layered composite structure from said mould.

A method for producing a vehicle composite component with a layer structure having a core layer in a molding tool, the core layer being formed with regions of different thickness is provided. Steps for this method may include placing a cover layer, in particular a preformed cover layer, which in particular forms an outer skin of the vehicle composite component, onto a mold base plate of the open molding tool; introducing a first fiber layer, which is impregnated with PU resin and has not been subjected to forming, between the cover layer and a first mold counterplate of the open molding tool; closing the molding tool and compression molding the first fiber layer, which is impregnated with PU resin, against the cover layer, as a result of which a preform with a first support layer containing the first fiber layer is formed and hardened while supplying heat.

A frame device for retaining and positioning sheet materials and possible reinforcing materials intended to be thermoformed to obtain objects made of composite material includes a first tubular element defining internally a first vacuum chamber for grasping by aspiration a first sheet material and a second tubular element defining internally a second vacuum chamber, separate from, and independent of the first vacuum chamber and configured for grasping by aspiration a second sheet material. The first tubular element and the second tubular element are fixed together permanently so as to define a grasping frame-structure configured as a single piece. A third vacuum chamber is defined in the grasping frame structure, separate and independent of the first and second vacuum chambers and configured for removing air from the zone that is interposed between the first and second sheet materials and which is intended for being possibly occupied by the reinforcing materials.

A method and apparatus for tacking and trimming a thermoplastic tow. A thermoplastic tow is received from a braiding system over a braided structure on a surface. The thermoplastic tow is tack welded to the braided structure. A portion of the thermoplastic tow is trimmed to thereby trim the thermoplastic tow received over the braided structure.

A manufacturing method contemplates performing vacuum-assisted resin infusion to enclose an elongated core within a cured composite laminate without employing a mold. Not relying upon an external mold enables the process to be efficiently performed for core shapes that are manufactured in low volumes. Typical resin infusion processes utilize flow media that induces bag bridging during vacuum draw in order to provide gaps facilitating resin flow. However, popular flow media also tends to impart directional aggregate forces during vacuum draw, which forces can deform the core since no mold is being used. To avoid unequal and non-dispersed directional forces from deforming the elongated core, a flow media is employed that is configured to disperse and/or reduce such forces. Some such flow media may be knitted so as to allow overlapping strands to slide over one another. Other flow media may ensure that strands are interleaved so that no one strand or group of strands is disposed outwardly of other strands along a substantial length of the strands, thus dispersing bag bridging forces in several directions and avoiding directional aggregate forces. However, such flow media may have inhibited resin flow relative to popular high-flow flow media, and thus new strategies have been developed to ensure appropriate wetting of fibrous reinforcement. An adjustable brace can also be employed to restrain the elongated core from deflecting during application of vacuum and/or resin infusion.

A composite comprises: a reinforcing element (10), an adhesive layer (14) made from an adhesive composition, and an elastomeric body made from an elastomeric matrix comprising an ethylene/alpha-olefin type elastomer and/or a polychloroprene elastomer. The adhesive composition comprises a resin based: on a polyphenol comprising an aromatic ring bearing two hydroxyl functions in the meta position relative to one another, the two positions ortho to one of the hydroxyl functions being unsubstituted; and/or on a monophenol comprising a six-membered aromatic ring bearing a single hydroxyl function, the two ortho positions being unsubstituted, or an ortho position and the para position being unsubstituted, and on a compound comprising an aromatic ring bearing two functions, one of these functions being a hydroxymethyl function and the other being an aldehyde function or a hydroxymethyl function.