In one embodiment, a method for making a high density structural composite includes depositing a plurality of fibrous materials on or adjacent a first plate or surface. A polymer liquid is deposited onto the plurality of fibrous materials to form a composite mixture. A first cyclic pressure is applied onto the composite mixture to compress the composite mixture. In some embodiments, the cyclic pressure may then be reduced to a valley pressure to complete a pressurization cycle. In some instances, the valley pressure may be below atmospheric pressure to induce trapped air and volatile gases to escape from the composite mixture before curing. The pressurization cycle may be repeated. A second pressure, which may be a constant pressure in some embodiments, may be applied to the composite mixture using, in some embodiments, a second plate until the polymer liquid has at least partially cured or partially solidified.

The present disclosure provides a thermally conductive article including a pad having first and second opposed major surfaces and a thickness therebetween. The thickness is formed of entangled thermally conductive fibers and at least a portion of the entangled thermally conductive fibers have at least one terminal end at the first opposed major surface, the opposed second major surface, or both. The pad is at least partially impregnated with a polymer. Another thermally conductive article is provided including a) a pad having first and second opposed major surfaces and a thickness therebetween; b) a first thermally conductive skin layer; and c) a second thermally conductive skin layer. The thickness of the pad is formed of aligned thermally conductive fibers, and at least a portion of the thermally conductive fibers have a terminal end at the first opposed major surface and the opposed second major surface. The first and second thermally conductive skin layers each include a polymeric matrix at least partially embedded in the terminal end of at least a portion of the thermally conductive fibers at the first and second major surfaces of the pad, respectively. Methods of making the thermally conductive articles are also provided.

The present disclosure provides a thermally conductive article including a pad having first and second opposed major surfaces and a thickness therebetween. The thickness is formed of entangled thermally conductive fibers and at least a portion of the entangled thermally conductive fibers have at least one terminal end at the first opposed major surface, the opposed second major surface, or both. The pad is at least partially impregnated with a polymer. Another thermally conductive article is provided including a) a pad having first and second opposed major surfaces and a thickness therebetween; b) a first thermally conductive skin layer; and c) a second thermally conductive skin layer. The thickness of the pad is formed of aligned thermally conductive fibers, and at least a portion of the thermally conductive fibers have a terminal end at the first opposed major surface and the opposed second major surface. The first and second thermally conductive skin layers each include a polymeric matrix at least partially embedded in the terminal end of at least a portion of the thermally conductive fibers at the first and second major surfaces of the pad, respectively. Methods of making the thermally conductive articles are also provided.

The present invention is aimed to provide a carbon fiber reinforced resin processed product which is almost free from the problems described above on a processed surface subjected to cutting or the like and has an end surface where generation of a burr is suppressed, has favorable surface properties, and surface nature, and particularly smoothness is excellent; and provides a carbon fiber reinforced resin processed product having an end surface which has fibers and a resin, wherein the end surface has a surface roughness (Rz) within a range from 5 μm to 50 μm.

The present invention is aimed to provide a carbon fiber reinforced resin processed product which is almost free from the problems described above on a processed surface subjected to cutting or the like and has an end surface where generation of a burr is suppressed, has favorable surface properties, and surface nature, and particularly smoothness is excellent; and provides a carbon fiber reinforced resin processed product having an end surface which has fibers and a resin, wherein the end surface has a surface roughness (Rz) within a range from 5 μm to 50 μm.

There is provided a method of forming a patterned anisotropic-comprising composite material, comprising inserting at least a part of a heated probe into a matrix to induce a local phase change around the probe within the matrix, the matrix being a matrix of thermo-reversible material and anisotropic fillers, and moving the heated probe within the matrix to form an alignment pattern of the anisotropic fillers comprised in the matrix. There is also provided a patterned anisotropic-comprising composite material formed from the method.

There is provided a method of forming a patterned anisotropic-comprising composite material, comprising inserting at least a part of a heated probe into a matrix to induce a local phase change around the probe within the matrix, the matrix being a matrix of thermo-reversible material and anisotropic fillers, and moving the heated probe within the matrix to form an alignment pattern of the anisotropic fillers comprised in the matrix. There is also provided a patterned anisotropic-comprising composite material formed from the method.

The present invention relates to a method for assembling particles having a long axis, a short axis and an average aspect ratio of 10-10,000. The method includes agitating a combination of a first solution, a second solution and the particles in any order to form a mixture wherein one of the first solution and the second solution is in the form of droplets dispersed in the other of the first solution and the second solution and the long axis of the particles is longer than a diameter of the droplets in the mixture, and continuing the agitation until the particles assemble into aggregates of particles with at least 30% of the particles aligned in parallel along the long axis. Aggregate or aggregate composites form by the method are also described.

Provided are a method for preparing a unidirectionally aligned discontinuous fiber reinforcement composite material, a unidirectionally aligned discontinuous fiber reinforcement composite material, and a sandwich structure. The method for preparing a unidirectionally aligned discontinuous fiber reinforcement composite material comprises discontinuously aligning short fibers on a polymer substrate in one direction by using an air-laid method.

Provided are a method for preparing a unidirectionally aligned discontinuous fiber reinforcement composite material, a unidirectionally aligned discontinuous fiber reinforcement composite material, and a sandwich structure. The method for preparing a unidirectionally aligned discontinuous fiber reinforcement composite material comprises discontinuously aligning short fibers on a polymer substrate in one direction by using an air-laid method.