Carbon fiber pre-pregs and methods for manufacturing thereof
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United States of America Patent
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Jul 23, 2019
Grant Date -
Jan 18, 2018
app pub date -
Jul 15, 2016
filing date -
Jul 15, 2016
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Abstract
Methods and components produced from carbon fiber pre-impregnated composite precursor materials (pre-preg) having enhanced flowability and moldability are provided. Discontinuous cut regions are introduced into a pre-preg. A sheet of pre-preg may be contacted with a patterned surface having a plurality of non-contiguous staggered cutters, so that the contacting creates discontinuous cuts in the pre-preg. A plurality of staggered discontinuous cut regions are formed in the plurality of continuous carbon fibers that define a first plurality of carbon fibers having a first length and a second plurality of carbon fibers having a second distinct length. The patterned surface may be provided on a cutter device that is a roller or a plate having the non-contiguous staggered cutters formed or disposed thereon. The discontinuous cut regions that are formed in the pre-preg reduce stiffness and improve moldability/flowability when forming carbon fiber polymeric composites, while retaining high strength levels.
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