A process and system are provided for introducing a blend of chopped and dispersed fibers on an automated production line amenable for inclusion in molding compositions as a blended fiber mat for structural applications. The blend of fibers are simultaneously supplied to an automated cutting machine illustratively including a rotary blade chopper disposed above a vortex supporting chamber. The blend of chopped fibers and binder form a chopped mat. The chopped mat has a veil mat placed on either side, and is consolidated with the veil mat using heated rollers maintained at the softening temperature of thermoplastic binder, with consolidated mats being amenable to being stored in rolls or as flat sheets. A charge pattern is made using the consolidated mat, and the charge pattern can be compression molded in a mold maintained at a temperature lower than the melting point of the thermoplastic fibers.

A process and system are provided for introducing a blend of chopped and dispersed fibers on an automated production line amenable for inclusion in molding compositions as a blended fiber mat for structural applications. The blend of fibers are simultaneously supplied to an automated cutting machine illustratively including a rotary blade chopper disposed above a vortex supporting chamber. The blend of chopped fibers and binder form a chopped mat. The chopped mat has a veil mat placed on either side, and is consolidated with the veil mat using heated rollers maintained at the softening temperature of thermoplastic binder, with consolidated mats being amenable to being stored in rolls or as flat sheets. A charge pattern is made using the consolidated mat, and the charge pattern can be compression molded in a mold maintained at a temperature lower than the melting point of the thermoplastic fibers.

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%.

Disclosed herein are pristine graphene sheets with columns formed of fullerene nanotubes between the graphene sheets for use as body armor, semiconductor, battery anode, solar panels, heat sinks, structural concrete members, structural steel members, precast concrete structural members, bridges, highways, streets, skyscrapers, sidewalks, foundations, dams, industrial plants, canals, airports, structural composites, aircraft, military equipment, and civil infrastructure.

Disclosed herein are pristine graphene sheets with columns formed of fullerene nanotubes between the graphene sheets for use as body armor, semiconductor, battery anode, solar panels, heat sinks, structural concrete members, structural steel members, precast concrete structural members, bridges, highways, streets, skyscrapers, sidewalks, foundations, dams, industrial plants, canals, airports, structural composites, aircraft, military equipment, and civil infrastructure.

A flexible insulation material may be configured to substantially reduce the amount of radiation transmitted therethrough by incorporating a reflective mat of high temperature fibers that withstand temperatures of at least 500° C. The flexible insulation may be stored and used over temperatures ranging from −270° C. to 5000° C. The mat may have optical properties to produce a transmittance of no more than 5% over a range of temperature from 500° C. to 5000 vC. The mat may include high temperature fibers such as carbon and/or silicon carbide and these fibers may be coupled by a binder in a non-woven fabric. The flexible insulation material may be configured in the Flexible Thermal Protection System of a deployable aerodynamic decelerator or a Hypersonic Inflatable Aerodynamic Decelerator and may be durably flexible.

A flexible insulation material may be configured to substantially reduce the amount of radiation transmitted therethrough by incorporating a reflective mat of high temperature fibers that withstand temperatures of at least 500° C. The flexible insulation may be stored and used over temperatures ranging from −270° C. to 5000° C. The mat may have optical properties to produce a transmittance of no more than 5% over a range of temperature from 500° C. to 5000 vC. The mat may include high temperature fibers such as carbon and/or silicon carbide and these fibers may be coupled by a binder in a non-woven fabric. The flexible insulation material may be configured in the Flexible Thermal Protection System of a deployable aerodynamic decelerator or a Hypersonic Inflatable Aerodynamic Decelerator and may be durably flexible.

Provided is a reinforcing fiber mat including a reinforcing fiber mat constituted by reinforcing fibers having an average fiber length of 3 to 100 mm. The reinforcing fibers satisfy the following i) to iv): i) a weight-average fiber width (Ww) of the reinforcing fibers satisfies the following Equation (1):
0.03 mm<Ww<5.0 mm   (1);
ii) an average fiber width dispersion ratio (Ww/Wn) defined as a ratio of the weight-average fiber width (Ww) to a number-average fiber width (Wn) of the reinforcing fibers is 1.8 or more and 20.0 or less; iii) a weight-average fiber thickness of the reinforcing fibers is smaller than the weight-average fiber width (Ww); and iv) a fiber width distribution of the reinforcing fibers included in the reinforcing fiber mat has at least two peaks.

Provided is a reinforcing fiber mat including a reinforcing fiber mat constituted by reinforcing fibers having an average fiber length of 3 to 100 mm. The reinforcing fibers satisfy the following i) to iv): i) a weight-average fiber width (Ww) of the reinforcing fibers satisfies the following Equation (1):
0.03 mm<Ww<5.0 mm   (1);
ii) an average fiber width dispersion ratio (Ww/Wn) defined as a ratio of the weight-average fiber width (Ww) to a number-average fiber width (Wn) of the reinforcing fibers is 1.8 or more and 20.0 or less; iii) a weight-average fiber thickness of the reinforcing fibers is smaller than the weight-average fiber width (Ww); and iv) a fiber width distribution of the reinforcing fibers included in the reinforcing fiber mat has at least two peaks.