A carbon-carbon composite preform including a plurality of layers including carbon fibers or carbon-precursor fibers, the layers include a first exterior layer defining a first major surface, a second exterior layer defining a second major surface, and at least one interior layer disposed between the first exterior layer and the second exterior layer, the at least one interior layer having a peripheral region that forms a portion of an outer surface of the preform. The preform includes needled fibers, where at least some needled fibers extend through two or more layers. The preform has an exterior region and a core region, where the exterior region includes at least the peripheral region of at least one interior layer. The needled fibers define a first needled fiber number density (NFND) in the exterior region and a second greater NFND in at least a portion of the core region.

A carbon-carbon composite preform including a plurality of layers including carbon fibers or carbon-precursor fibers, the layers include a first exterior layer defining a first major surface, a second exterior layer defining a second major surface, and at least one interior layer disposed between the first exterior layer and the second exterior layer, the at least one interior layer having a peripheral region that forms a portion of an outer surface of the preform. The preform includes needled fibers, where at least some needled fibers extend through two or more layers. The preform has an exterior region and a core region, where the exterior region includes at least the peripheral region of at least one interior layer. The needled fibers define a first needled fiber number density (NFND) in the exterior region and a second greater NFND in at least a portion of the core region.

A process and system are provided for introducing chopped and dispersed carbon fibers on an automated production line amenable for inclusion in molding compositions, including the debundling of many carbon fibers collectively forming a tow into dispersed chopped carbon fibers that form a filler that undergoes plasma treatment prior to introducing coating silanes to uniformly increase bonding sites for coupling to a thermoset matrix. By exposing carbon tow to a plasma discharge, the carbon tow debundles and is used to form sheets of molding compositions with chopped dispersed fibers added to the composition, as the sheets move along a conveyor belt on the automated production line and at least one plasma generator mounted above the conveyor belt ionizes the carbon fibers. With resort to deionized air to mix plasma-treated chopped fibers, still further dispersion results.

Fiber-reinforced nonwoven composites having a wide variety of uses (e.g., leisure goods, aerospace, electronics, equipment, energy generation, mass transport, automotive parts, marine, construction, defense, sports and/or the like) are provided. The fiber-reinforced nonwoven composite includes a plurality of carbon fibers and a polymer matrix. The plurality of carbon fibers have an average fiber length from about 50 mm to about 125 mm. The fiber-reinforced nonwoven composite comprises a theoretical void volume from about 0% to about 10%.

Fiber-reinforced nonwoven composites having a wide variety of uses (e.g., leisure goods, aerospace, electronics, equipment, energy generation, mass transport, automotive parts, marine, construction, defense, sports and/or the like) are provided. The fiber-reinforced nonwoven composite includes a plurality of carbon fibers and a polymer matrix. The plurality of carbon fibers have an average fiber length from about 50 mm to about 125 mm. The fiber-reinforced nonwoven composite comprises a theoretical void volume from about 0% to about 10%.

A thermoplastic bonded preform and method of manufacturing the preform are disclosed. The preform comprises a primary fiber comprising little or no sizing; a mechanical fiber; and a thermoplastic.

A thermoplastic bonded preform and method of manufacturing the preform are disclosed. The preform comprises a primary fiber comprising little or no sizing; a mechanical fiber; and a thermoplastic.

The present invention relates to a nonwoven fabric or nonwoven composite material comprising the nonwoven fabric for shielding and absorbing electromagnetic waves, manufactured by using a carbon fiber plated with metal (copper and nickel) produced in an electroless or electrolysis continuous process. The nonwoven fabric of the present invention is thinner and stronger than the conventional art, and has an advantage of being capable of controlling conductivity by controlling only the content of the carbon fiber plated with metal, without need for further addition of conductive powder.

The present invention relates to a nonwoven fabric or nonwoven composite material comprising the nonwoven fabric for shielding and absorbing electromagnetic waves, manufactured by using a carbon fiber plated with metal (copper and nickel) produced in an electroless or electrolysis continuous process. The nonwoven fabric of the present invention is thinner and stronger than the conventional art, and has an advantage of being capable of controlling conductivity by controlling only the content of the carbon fiber plated with metal, without need for further addition of conductive powder.

A thermoplastic bonded preform and method of manufacturing the preform are disclosed. The preform comprises a primary fiber comprising little or no sizing; a mechanical fiber; and a thermoplastic.