A process for aligning discontinuous fibers, and composite products and mats comprised of highly aligned discontinuous fibers, including products of the process. Aligned discontinuous fiber composite products include a matrix of fibers, each fiber having a longitudinal fiber axis, the composite comprising a free, uncut edge extending along an edge axis. The longitudinal fiber axis of a majority of the fibers in the composite product are aligned within a predetermined alignment tolerance of an alignment axis non-parallel to the edge axis. Aligned discontinuous fiber mats may have a first areal density of fibers in a first region of the composite located inward relative to the free, uncut edge, and a second area density at or adjacent to the free, uncut edge.

Disclosed is a method of producing a carbon-resin composite material, the method including: the step of preparing a composite structure in which a carbon linear body containing a carbon material, and a resin linear body containing at least one of a thermoplastic resin or a thermosetting resin are regularly arranged; and the step of heating the composite structure.

A hybrid preform comprises a bundle of unidirectionally aligned fibers, and at least one partial cut that extends part of the way, but not all of the way, through a transverse cross section of the bundle of fibers at least one location along the length of the bundle.

Interlaminar features of a composite structure are laid up by placing and steering individual chopped fiber pre-preg segments onto a substrate.

Interlaminar features of a composite structure are laid up by placing and steering individual chopped fiber pre-preg segments onto a substrate.

A mold for resin impregnation molding includes an accommodating portion which is able to accommodate a container body around which a fiber bundle is wound, a storage portion which is able to store an uncured resin having fluidity, a flow path which causes the resin to flow from the storage portion to the accommodating portion, and a pressure control unit which controls a pressure which causes the resin stored in the storage portion to flow through the flow path to the accommodating portion.

A mold for resin impregnation molding includes an accommodating portion which is able to accommodate a container body around which a fiber bundle is wound, a storage portion which is able to store an uncured resin having fluidity, a flow path which causes the resin to flow from the storage portion to the accommodating portion, and a pressure control unit which controls a pressure which causes the resin stored in the storage portion to flow through the flow path to the accommodating portion.

An intermediate base material is provided that is excellent in the conformity to three-dimensional shapes and that, when formed into a fiber reinforced plastic, develops good surface quality and high mechanical properties.

According to one aspect, an incised prepreg is provided that has, in at least a partial region in a prepreg that contains unidirectionally oriented reinforcing fibers and a resin, a plurality of incisions that divide reinforcing fibers, wherein, in the case where a population is made up of the numbers of incisions contained in ten small circular regions of 10 mm in diameter randomly selected in the aforementioned region, a mean value for the population is 10 or greater and a coefficient of variation therefor is within 20%.

The present disclosure provides an apparatus that includes a fiber gun. In an embodiment, the apparatus may controllably cut one or more fibers into one or more fiber segments. In an embodiment, the apparatus may controllably shape one or more fibers into different shapes (e.g., from loops into substantially straight fibers). In an embodiment, the apparatus may controllably position the one or more fiber segments onto a supporting member (e.g., a composite component). For example, the apparatus may include a robot that may controllably move the fiber gun relative to a supporting member and align the fiber gun such that the one or more fiber segments are controllably positioned on the supporting member. The apparatus may further include a controller that at least partially controls operation of the apparatus.

The present disclosure provides an apparatus that includes a fiber gun. In an embodiment, the apparatus may controllably cut one or more fibers into one or more fiber segments. In an embodiment, the apparatus may controllably shape one or more fibers into different shapes (e.g., from loops into substantially straight fibers). In an embodiment, the apparatus may controllably position the one or more fiber segments onto a supporting member (e.g., a composite component). For example, the apparatus may include a robot that may controllably move the fiber gun relative to a supporting member and align the fiber gun such that the one or more fiber segments are controllably positioned on the supporting member. The apparatus may further include a controller that at least partially controls operation of the apparatus.