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WO2001092002A3 - Method for consolidation for random carbon fiber orientation and for forming a carbon fiber preform - Google Patents

Method for consolidation for random carbon fiber orientation and for forming a carbon fiber preform Download PDF

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Publication number
WO2001092002A3
WO2001092002A3 PCT/US2001/017983 US0117983W WO0192002A3 WO 2001092002 A3 WO2001092002 A3 WO 2001092002A3 US 0117983 W US0117983 W US 0117983W WO 0192002 A3 WO0192002 A3 WO 0192002A3
Authority
WO
WIPO (PCT)
Prior art keywords
carbon fiber
forming
arrangement
layer
heat
Prior art date
Application number
PCT/US2001/017983
Other languages
French (fr)
Other versions
WO2001092002A2 (en
WO2001092002A9 (en
Inventor
Mark Sloan
Richard D Blackmore
William M Lepola
Original Assignee
Ihc Rehabilitation Products
Mark Sloan
Richard D Blackmore
William M Lepola
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ihc Rehabilitation Products, Mark Sloan, Richard D Blackmore, William M Lepola filed Critical Ihc Rehabilitation Products
Priority to AU2001284641A priority Critical patent/AU2001284641A1/en
Publication of WO2001092002A2 publication Critical patent/WO2001092002A2/en
Publication of WO2001092002A3 publication Critical patent/WO2001092002A3/en
Publication of WO2001092002A9 publication Critical patent/WO2001092002A9/en

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    • B32—LAYERED PRODUCTS
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    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
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    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Reinforced Plastic Materials (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

The present invention is a method of forming a composite including a carbon fiber layer surrounded by at least a single layer of non-woven fibers both above and below the carbon fiber layer. The layer(s) of carbon fiber and the layers of non-woven fibers are consolidated with a unique needle-punching method. According to another aspect of the invention, the layer(s) of carbon fiber and the layers of non-woven fibers are consolidated with a stitching method. The present invention also provides a method of forming a preform part, comprising a number of steps. First, arrangement of carbon fibers is coated with a binder, which is either a liquid or dry adhesive. Next, the carbon fiber arrangement is placed on a forming surface. The forming surface can be either a curved or generally flat surface. Third, pressure is applied to the carbon fiber arrangement. A vacuum bag or portions of a conventional mold can be used to apply pressure to the arrangement. Lastly, heat is applied to the carbon fiber arrangement to set the binder. Heat can be applied in a number of ways, including applying an electric current to the carbon fibers to resistively heat the carbon fiber arrangement. Once a sufficient quantity of heat has been applied to set the binder, the resulting preform part is allowed to cool and then removed from the forming surface. The preform part is then ready to be injected with resin and used with a mold to form a finished part.
PCT/US2001/017983 2000-06-02 2001-06-01 Method for consolidation for random carbon fiber orientation and for forming a carbon fiber preform WO2001092002A2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2001284641A AU2001284641A1 (en) 2000-06-02 2001-06-01 Method for consolidation for random carbon fiber orientation and for forming a carbon fiber preform

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US20943500P 2000-06-02 2000-06-02
US60/209,435 2000-06-02
US21350900P 2000-06-22 2000-06-22
US60/213,509 2000-06-22

Publications (3)

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WO2001092002A2 WO2001092002A2 (en) 2001-12-06
WO2001092002A3 true WO2001092002A3 (en) 2002-12-27
WO2001092002A9 WO2001092002A9 (en) 2004-05-21

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RU2558904C1 (en) * 2012-08-01 2015-08-10 Тейдзин Лимитед Mat with arbitrary orientation of fibres and moulded product of fibre-reinforced composite material

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WO2004041528A2 (en) 2002-11-01 2004-05-21 Bell Helicopter Textron Inc. Method and apparatus for z-direction reinforcement of composite laminates
EP2635417B1 (en) * 2010-11-03 2015-09-02 SGL Automotive Carbon Fibers GmbH & Co. KG Pile layer having curved bundles
EP2511080B1 (en) 2011-04-12 2018-07-11 Fundacion Tecnalia Research & Innovation Device for the preparation of preforms of carbon fiber-reinforced components
US20140003923A1 (en) 2012-07-02 2014-01-02 Peter Finnigan Functionally graded composite fan containment case
US9771669B2 (en) 2013-11-08 2017-09-26 Georgia Tech Research Corporation Use, stabilization and carbonization of polyacrylonitrile/carbon composite fibers
JP2017531104A (en) 2014-10-08 2017-10-19 ジョージア テック リサーチ コーポレイション High strength and high modulus carbon fiber
WO2018102282A1 (en) * 2016-11-30 2018-06-07 Continental Structural Plastics, Inc. Hybrid fiber based molding thermoplastic article and process of forming same
IT201800003741A1 (en) * 2018-03-19 2019-09-19 Freni Brembo Spa METHOD FOR MAKING A FIBROUS PREFORM AND A FIBROUS PREFORM SO OBTAINED
US11571861B2 (en) * 2019-10-25 2023-02-07 Spirit Aerosystems, Inc. System and method for thermoplastic welding using an induced thermal gradient
CN113510946B (en) * 2021-04-20 2022-08-30 济南大学 Carbon fiber composite material molding press
CN114836898A (en) * 2022-06-02 2022-08-02 江苏天鸟高新技术股份有限公司 Needled carbon fiber net felt and preparation method and application thereof

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RU2558904C1 (en) * 2012-08-01 2015-08-10 Тейдзин Лимитед Mat with arbitrary orientation of fibres and moulded product of fibre-reinforced composite material

Also Published As

Publication number Publication date
WO2001092002A2 (en) 2001-12-06
AU2001284641A1 (en) 2001-12-11
WO2001092002A9 (en) 2004-05-21

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