A method and apparatus for fabricating a short length carbon fiber preform with a through thickness reinforcement is disclosed herein. The starting media for fabricating a net shape (e.g., annular disc) may meet specific requirements including a sufficient fiber volume and a binding mechanism compatible with the needle-punching process.

A carbon fiber non-woven cloth that satisfies at least one of the following (1) to (3): (1) includes a carbon fiber that does not substantially include an organic material, (2) includes a carbon fiber that does not form a strand, or (3) includes a carbon fiber that is a retrieved product from a composite material including the carbon fiber and an organic substance.

A carbon fiber non-woven cloth that satisfies at least one of the following (1) to (3): (1) includes a carbon fiber that does not substantially include an organic material, (2) includes a carbon fiber that does not form a strand, or (3) includes a carbon fiber that is a retrieved product from a composite material including the carbon fiber and an organic substance.

A carbon fiber non-woven cloth that satisfies at least one of the following (1) to (3): (1) includes a carbon fiber that includes an organic substance, and a carbon fiber that does not substantially include an organic material, (2) includes a carbon fiber that forms a strand, and a carbon fiber that does not form a strand, or (3) includes a carbon fiber that is not a retrieved product from a composite material including a carbon fiber and an organic substance, and a carbon fiber that is a retrieved product from a composite material including a carbon fiber and an organic substance.

A carbon fiber non-woven cloth that satisfies at least one of the following (1) to (3): (1) includes a carbon fiber that includes an organic substance, and a carbon fiber that does not substantially include an organic material, (2) includes a carbon fiber that forms a strand, and a carbon fiber that does not form a strand, or (3) includes a carbon fiber that is not a retrieved product from a composite material including a carbon fiber and an organic substance, and a carbon fiber that is a retrieved product from a composite material including a carbon fiber and an organic substance.

Methods of making a composite material may include the steps of depositing a plurality of fullerenes on a first graphene sheet forming a bottom plate, placing a second graphene sheet forming a top plate on a top of the plurality of fullerenes, and fusing the plurality of fullerenes to the first graphene sheet forming the bottom plate and the second graphene sheet forming the top plate, wherein the plurality of fullerenes are converted to fullerene-derived carbon columns, and wherein the composite material comprises a tensile strength in an x-axis parallel to the plane of the graphene sheets of at least 20 GPa.

Methods of making a composite material may include the steps of depositing a plurality of fullerenes on a first graphene sheet forming a bottom plate, placing a second graphene sheet forming a top plate on a top of the plurality of fullerenes, and fusing the plurality of fullerenes to the first graphene sheet forming the bottom plate and the second graphene sheet forming the top plate, wherein the plurality of fullerenes are converted to fullerene-derived carbon columns, and wherein the composite material comprises a tensile strength in an x-axis parallel to the plane of the graphene sheets of at least 20 GPa.

A carbon fiber nonwoven fabric sheet 15 contains discontinuous carbon fibers. The carbon fiber nonwoven fabric sheet 15 is an elongated parallel web 14 in which two or more rectangular fiber webs 10 having carbon fibers oriented substantially in one direction are stacked in the same direction with their end portions shifted from each other. With a method for producing the same, a fiber web is formed by opening discontinuous carbon fibers using a carding machine, and orienting the carbon fibers substantially in one direction, rectangular fiber webs 10 are formed by cutting the fiber web in a width direction or an oblique direction, an elongated parallel web 14 is formed by stacking the rectangular fiber webs 10 on each other with their end portions shifted from each other, and a carbon fiber nonwoven fabric sheet 15 is obtained by cutting both ends of the elongated parallel web 14. A carbon fiber reinforced resin molded body according to the present invention contains the carbon fiber nonwoven fabric sheet and a matrix resin. As a result, the present invention provides a carbon fiber nonwoven fabric sheet that can be used in the same manner as that for a uniaxial sheet constituted of a continuous carbon fiber sheet, a method for producing the same, and a carbon fiber reinforced resin molded body.

A carbon fiber nonwoven fabric sheet 15 contains discontinuous carbon fibers. The carbon fiber nonwoven fabric sheet 15 is an elongated parallel web 14 in which two or more rectangular fiber webs 10 having carbon fibers oriented substantially in one direction are stacked in the same direction with their end portions shifted from each other. With a method for producing the same, a fiber web is formed by opening discontinuous carbon fibers using a carding machine, and orienting the carbon fibers substantially in one direction, rectangular fiber webs 10 are formed by cutting the fiber web in a width direction or an oblique direction, an elongated parallel web 14 is formed by stacking the rectangular fiber webs 10 on each other with their end portions shifted from each other, and a carbon fiber nonwoven fabric sheet 15 is obtained by cutting both ends of the elongated parallel web 14. A carbon fiber reinforced resin molded body according to the present invention contains the carbon fiber nonwoven fabric sheet and a matrix resin. As a result, the present invention provides a carbon fiber nonwoven fabric sheet that can be used in the same manner as that for a uniaxial sheet constituted of a continuous carbon fiber sheet, a method for producing the same, and a carbon fiber reinforced resin molded body.

A method for arranging nanotube elements within nanotube fabric layers and films is disclosed. A directional force is applied over a nanotube fabric layer to render the fabric layer into an ordered network of nanotube elements. That is, a network of nanotube elements drawn together along their sidewalls and substantially oriented in a uniform direction. In some embodiments this directional force is applied by rolling a cylindrical element over the fabric layer. In other embodiments this directional force is applied by passing a rubbing material over the surface of a nanotube fabric layer. In other embodiments this directional force is applied by running a polishing material over the nanotube fabric layer for a predetermined time. Exemplary rolling, rubbing, and polishing apparatuses are also disclosed.