METHOD OF MAKING A COMPOSITE PREFORM

1 . A method to form a part, comprising:

forming a pattern with a commingled yarn, wherein the commingled yarn comprises thermoplastic resin filaments formed from a thermoplastic material and reinforcing filaments formed from a reinforcing material, and wherein the reinforcing material has a glass transition temperature and/or a decomposition temperature that is higher than a glass transition temperature of the thermoplastic material;

attaching the pattern by sewing to a carrier material to form a preform; and

using the preform to form the part,

wherein a thickness of the commingled yarn ( 10 ) is 0.1 millimeter to 5 millimeters, wherein the thickness is measured along a longest linear dimension that spans a cross-section of the yarn taken in a t-x plane.

2 . The method of claim 1 , wherein the commingled yarn consists of thermoplastic resin filaments formed from a thermoplastic material and reinforcing filaments formed of a reinforcing material, wherein the reinforcing material has a glass transition temperature and/or a decomposition temperature that is higher than a glass transition temperature of the thermoplastic material.

3 . The method of claim 1 , comprising disposing the preform in a mold; and heating the preform to melt the thermoplastic resin filaments and form a thermoplastic resin matrix that wets out the reinforcing filaments, to form a consolidated preform; or further comprising stacking two or more preforms, heating the preforms to melt the thermoplastic resin filaments and form a thermoplastic resin matrix that wets out the reinforcing filaments, to form a consolidated stack.

4 . The method of claim 3 , further comprising holding the preform under a pressure of greater than atmospheric pressure as the thermoplastic resin matrix wets out the reinforcing filaments and as the thermoplastic resin matrix cools.

5 . The method of claim 3 , further comprising inserting the consolidated preform in a mold and injection molding resin over the consolidated preform.

6 . The method of claim 1 , wherein the commingled yarn is formed from thermoplastic resin filaments and reinforcing filaments by braiding, twisting, spinning, wrapping, air entangling, mechanically intertwining, or a combination comprising at least one of the foregoing.

7 . The method of claim 1 , wherein attaching comprises stitching, spot-melting, ultra-sonic welding, heat-staking, adhesive deposition, or a combination comprising at least one of the foregoing.

8 . The method of claim 1 , wherein attaching comprises holding the commingled yarn in place on the carrier material with a fixing thread stitched to the carrier material.

9 . The method of claim 1 , further comprising arranging a distribution of thermoplastic filaments and reinforcing filaments in the commingled yarn.

10 . The method of claim 1 , further comprising forming a hole in the part without damaging the reinforcing filaments.

11 . A composite part formed by the method of claim 1 .

12 . A composite part, comprising:

a pattern of reinforcing filaments, wherein the part has a force flux during use, and wherein the reinforcing filaments are aligned with the force flux; and

a thermoplastic resin matrix;

wherein the reinforcing filaments are formed of a reinforcing material different from a thermoplastic material of the thermoplastic resin matrix, wherein the reinforcing filaments are stiffer and of a higher tensile strength than the thermoplastic resin matrix, and wherein the thermoplastic resin matrix is bonded to the reinforcing filaments forming a commingled yarn,

wherein a thickness of the commingled yarn ( 10 ) is 0.1 millimeter to 5 millimeters, wherein the thickness is measured along a longest linear dimension that spans a cross-section of the commingled yarn ( 10 ) taken in a t-x plane.

13 . The composite part of claim 12 , wherein the reinforcing filaments are substantially continuous throughout the part.

14 . The composite part of claim 12 , comprising a hole therethrough, wherein a portion of the reinforcing filaments are disposed tangentially to an edge of the hole along a perimeter of the hole.

15 . The composite part of claim 12 , wherein the thermoplastic resin filaments comprise polycarbonates, polypropylenes, polyethylenes, polystyrenes, polyvinyls, polyethylene terephthalates, polybutylene terephthalates, acrylics, nylons, thermoplastic polyurethanes, polyacetals, polyphenylene sulfides, cycloolefin copolymers, thermotropic polyesters, or a combination comprising at least one of the foregoing.

16 . A composite preform comprising:

a carrier material; and

a commingled yarn;

wherein the commingled yarn comprises thermoplastic resin filaments formed from a thermoplastic material and reinforcing filaments formed from a reinforcing material;

wherein the reinforcing filaments are stiffer and have a higher tensile strength than the thermoplastic resin filaments;

wherein the commingled yarn is attached to the carrier material in a pattern; and

wherein a thickness of the commingled yarn is 0.1 millimeter to 5 millimeters, wherein the thickness is measured along a longest linear dimension that spans a cross-section of the yarn taken in a t-x plane.

17 . The composite preform of claim 16 , wherein the commingled yarn in the pattern is substantially continuous.

18 . The composite preform of claim 16 , further comprising a fixing thread, wherein the fixing thread comprises thermoplastic resin filaments, reinforcing filaments, or a combination comprising at least one of the foregoing.

19 . (canceled)

20 . The composite part preform of claim 16 , wherein the commingled yarn is continuous throughout the preform.