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    Pre-consolidation of thermoplastic fiber preforms and method of making the same
    1.
    发明授权
    Pre-consolidation of thermoplastic fiber preforms and method of making the same 有权

    公开(公告)号：US11458651B2

    公开(公告)日：2022-10-04

    申请号：US16789580

    申请日：2020-02-13

    申请人： COATS & CLARK, INC.

    发明人： Probir Kumar Guha ,  Gokhan K. Coban

    IPC分类号： B29B11/16 ,  B29B11/12 ,  B29K101/12

    摘要： A process is provided for forming a pre-consolidated fiber preform for use in a molding process. The process includes layering a plurality of preform sheets on a pre-consolidation mold. Heating the plurality of preform sheets to a first temperature. Applying a first pressure to the plurality of preform sheets using the pre-consolidated mold. Maintaining the first temperature and the first pressure and heating for a first duration of time. A second pressure and a second temperature are then applied to the plurality of preform sheets for a second duration of time.

    MULTIPLE LAYER ARTICLE WITH INTERACTIVE REINFORCEMENTS LINEAR RIBBON FIBER REINFORCEMENT FOR COMPOSITE FORMS
    2.
    发明申请
    MULTIPLE LAYER ARTICLE WITH INTERACTIVE REINFORCEMENTS LINEAR RIBBON FIBER REINFORCEMENT FOR COMPOSITE FORMS 有权

    公开(公告)号：US20210008816A1

    公开(公告)日：2021-01-14

    申请号：US16982751

    申请日：2019-03-19

    申请人： COATS & CLARK, INC.

    发明人： Probir Kumar Guha

    IPC分类号： B29C70/24 ,  B29C70/46 ,  B29C43/22 ,  B29C43/30 ,  B32B5/26 ,  B32B17/02 ,  B32B27/12 ,  B32B9/04 ,  B32B7/09

    摘要： A form for a thin reinforced composite material includes a plurality of separate linear fiber strips, each having a rectangular cross section composed of reinforcement fibers. The linear fiber strips laid out in a two-dimensional base layer defining a shape of the form. A first successive layer formed with the plurality of separate linear fiber strips contacting the base layer, the linear fiber strips laid out in the first successive layer interspersed from the separate linear fiber strips in the two-dimensional base layer. A method of forming the form includes arranging the plurality of separate linear fiber strips on a substrate and tacking the plurality of separate linear fiber strips to the substrate with a plurality of stitches. A method of forming a unitary reinforced composite component from the form is further provided. The resulting component having high strength and light weight and being efficient to manufacture.

    FIBER PREFORM AND METHOD OF MAKING THE SAME
    3.
    发明申请
    FIBER PREFORM AND METHOD OF MAKING THE SAME 有权

    公开(公告)号：US20210237316A1

    公开(公告)日：2021-08-05

    申请号：US17164021

    申请日：2021-02-01

    申请人： COATS & CLARK, INC.

    发明人： Probir Kumar Guha

    IPC分类号： B29B11/16 ,  B29C65/62 ,  B29C70/22

    摘要： A fiber preform for use in a composite material molding process is provided that includes a fiber bundle containing reinforcing fibers. The fiber bundle arranged in parallel switchbacks forming a first layer of the fiber preform. The parallel switchbacks define a principal orientation. A roving is provided that contains reinforcing fibers in a coating. The roving forms stitches on the fiber bundle in a direction substantially perpendicular to the switchbacks so the stitches join the fiber bundle to itself. A method of forming such a fiber preform includes the fiber bundle in the parallel switchbacks being arranged to form the first layer of the fiber preform. The roving forms stitches on the fiber bundle in a direction perpendicular to the switchbacks to join the fiber bundle to itself.

    SELECTIVE COMMINGLED FIBER BUNDLE PREFORM HAVING INTEGRAL OPTICAL FIBER STRAIN SENSOR
    5.
    发明申请
    SELECTIVE COMMINGLED FIBER BUNDLE PREFORM HAVING INTEGRAL OPTICAL FIBER STRAIN SENSOR 有权

    公开(公告)号：US20210053304A1

    公开(公告)日：2021-02-25

    申请号：US16998073

    申请日：2020-08-20

    申请人： COATS & CLARK, INC.

    发明人： Probir Kumar Guha

    IPC分类号： B29C70/88 ,  B29B11/16 ,  B29B11/04 ,  B29C70/48 ,  G01K11/32

    摘要： A form for a vehicle component includes a commingled fiber bundle composed of thermoplastic fibers and a reinforcement fiber. The reinforcement fiber being glass fibers, aramid fibers, carbon fibers, or a combination thereof. The commingled fiber bundle is laid out in a two-dimensional base layer that defines a shape of the form. An optical fiber is stitched to the commingled fiber bundle. A method of forming a unitary reinforced composite component having a sensor system includes the form being placed onto a mold platen. The preform is heated to promote fusion of the thermoplastic fibers therein. The preform is cooled until solidified with contours of the component. The vehicle component is then removed from the mold platen.

    PRE-CONSOLIDATION OF THERMOPLASTIC FIBER PREFORMS AND METHOD OF MAKING THE SAME
    6.
    发明申请
    PRE-CONSOLIDATION OF THERMOPLASTIC FIBER PREFORMS AND METHOD OF MAKING THE SAME 审中-公开

    公开(公告)号：US20200262107A1

    公开(公告)日：2020-08-20

    申请号：US16789580

    申请日：2020-02-13

    申请人： COATS & CLARK, INC.

    发明人： Probir Kumar Guha ,  Gokhan K. Coban

    IPC分类号： B29B11/16 ,  B29B11/12

    摘要： A process is provided for forming a pre-consolidated fiber preform for use in a molding process. The process includes layering a plurality of preform sheets on a pre-consolidation mold. Heating the plurality of preform sheets to a first temperature. Applying a first pressure to the plurality of preform sheets using the pre-consolidated mold. Maintaining the first temperature and the first pressure and heating for a first duration of time. A second pressure and a second temperature are then applied to the plurality of preform sheets for a second duration of time.

    THREE DIMENSIONAL PREFORM CREATED BY PRECONSOLIDATION OF THERMAL PLASTIC STITCHED SHEET
    8.
    发明申请
    THREE DIMENSIONAL PREFORM CREATED BY PRECONSOLIDATION OF THERMAL PLASTIC STITCHED SHEET 有权

    公开(公告)号：US20220305693A1

    公开(公告)日：2022-09-29

    申请号：US17210802

    申请日：2021-03-24

    申请人： COATS & CLARK, INC.

    发明人： Probir Kumar Guha ,  George Han

    IPC分类号： B29B11/16 ,  B29B11/04

    摘要： A two dimensional unitary preform sheet including a substrate and a fiber bundle arranged on the substrate and attached to the substrate by a plurality of stitches of a thread, which may be a thermoplastic thread. The two dimensional unitary preform sheet is configurable into a three dimensional preform. According to embodiments, the fiber bundle includes carbon fibers, glass fibers, aramid fibers, or a combination thereof. According to embodiments, the two dimensional unitary preform sheet is cut in a pattern that is foldable into the three dimensional preform. A method for making a three dimensional preform is also provided, which includes forming a two dimensional unitary preform sheet and placing the two dimensional unitary preform in a press to bend the two dimensional unitary preform into the shape of the three dimensional preform.