The provided articles and methods use a non-woven fibrous web containing 60-100 wt % of oxidized polyacrylonitrile fibers; and 0-40 wt % of reinforcing fibers having outer surfaces comprised of a polymer with a melting temperature of from 100° C. to 300° C. The non-woven fibrous web has an average bulk density of from 15 kg/m.sup.3 to 50 kg/m.sup.3, with the plurality of fibers substantially entangled along directions perpendicular to a major surface of the non-woven fibrous web. Optionally, the oxidized polyacrylonitrile fibers can have a crimped configuration. Advantageously, these articles can display a combination of low thermal conductivity, high tensile strength, and flame resistance.

A method for producing a composite material. The method includes the steps of producing an initial dry preform, formed from unidirectional continuous dry fibers, applying non-woven filaments to a first main face of the dry preform, and needling the filaments with a needling device. The needling device includes a plurality of needles, each provided with at least one notch, so that filaments are driven by the needles and arranged in a direction substantially perpendicular to the continuous fibers of the dry perform. The method includes the further step of impregnating the dry preform with an impregnation polymer, the impregnation polymer constituting the matrix of the composite material part.

The provided articles and methods use a non-woven fibrous web containing 60-100 wt % of oxidized polyacrylonitrile fibers; and 0-40 wt % of reinforcing fibers having outer surfaces comprised of a polymer with a melting temperature of from 100° C. to 300° C. The non-woven fibrous web has an average bulk density of from 15 kg/m.sup.3 to 50 kg/m.sup.3, with the plurality of fibers substantially entangled along directions perpendicular to a major surface of the non-woven fibrous web. Optionally, the oxidized polyacrylonitrile fibers can have a crimped configuration. Advantageously, these articles can display a combination of low thermal conductivity, high tensile strength, and flame resistance.

Provided are a carbon fibre thermoplastic resin prepreg which is a carbon fibre prepreg obtained by impregnating a PAN-based carbon fibre in which the average fibre fineness of a single fibre is 1.0 dtex to 2.4 dtex with a thermoplastic resin, wherein the thermoplastic resin satisfies 20<(FM/FS)<40 (where FM: flexural modulus (MPa) of a resin sheet comprising only the thermoplastic resin, and FS: flexural strength (MPa) of the resin sheet), a method for manufacturing the same, and a carbon fibre composite material employing the carbon fibre prepreg.

Disclosed is a non-flammable thermal insulating composite substrate for motor vehicles including: a textile component constituted by a layer of needle-sewn non-woven fabric composed of a percentage of pre-oxidized polyacrylonitrile fiber included between 40% and 70%, preferably 58% and of the remaining percentage of polyethylene glycol-terephthalate fiber, the textile component having weight preferably 400 gr/m.sup.2; and a barrier fixed to the textile component using a spreading process, constituted by a thermoplastic resin based on low density polyethylene added with non-halogen flame retardants, the barrier having weight preferably 100 gr/m.sup.2. The composite substrate has the following features: a thickness included between 2 mm and 5 mm, preferably 3.8 mm; a weight included between 300 gr/m.sup.2 and 700 gr/m.sup.2, preferably 500 gr/m.sup.2; odorless; no emission of fumes; dimensionally stable, even at heatstroke, with a maximum variation of 1%; and non-flammability.

A method of making a carbonized preform for a carbon-carbon composite brake disk may comprise: stacking a plurality of textile fabric layers, each textile fabric layer in the plurality of textile fabric layers including oxidized polyacrylonitrile (PAN) fibers, each textile fabric layer in the plurality of textile fabric layers being more uniform than a typical fabric layer formed from cross-lapping; each fabric layer being thinner than a typical fabric layer from cross-lapping, needling the plurality of textile fabric layers to form a needled non-woven board; cutting a fibrous preform from the needled non-woven board; and carbonizing the fibrous preform. The resultant non-woven carbonized preform maintains a higher fiber volume and more consistent properties throughout than what would otherwise be achieved using a typical fabric layer from cross-lapping.

A method of manufacturing a design-imprinted molded article comprises providing a glass mold of a desired shape, that further comprises a desired shaped concave and a desired shaped rim, providing a plurality of sheets of polyacrylonitrile fibers, providing at least one design cutout of polyacrylonitrile fibers, overlaying the plurality of sheets on the surface of the desired shaped concave and desired shaped rim, overlaying the design cutout on the plurality of sheets, and applying high heat to the glass mold.

A method of manufacturing a design-imprinted molded article comprises providing a glass mold of a desired shape, that further comprises a desired shaped concave and a desired shaped rim, providing a plurality of sheets of polyacrylonitrile fibers, providing at least one design cutout of polyacrylonitrile fibers, overlaying the plurality of sheets on the surface of the desired shaped concave and desired shaped rim, overlaying the design cutout on the plurality of sheets, and applying high heat to the glass mold.

The provided articles and methods use a non-woven fibrous web containing 60-100 wt % of oxidized polyacrylonitrile fibers; and 0-40 wt % of reinforcing fibers having outer surfaces comprised of a polymer with a melting temperature of from 100 C. to 300 C. The non-woven fibrous web has an average bulk density of from 15 kg/m.sup.3 to 50 kg/m.sup.3, with the plurality of fibers substantially entangled along directions perpendicular to a major surface of the non-woven fibrous web. Optionally, the oxidized polyacrylonitrile fibers can have a crimped configuration. Advantageously, these articles can display a combination of low thermal conductivity, high tensile strength, and flame resistance.

A method of manufacturing a design-imprinted molded article comprises providing a glass mold of a desired shape, that further comprises a desired shaped concave and a desired shaped rim, providing a plurality of sheets of polyacrylonitrile fibers, providing at least one design cutout of polyacrylonitrile fibers, overlaying the plurality of sheets on the surface of the desired shaped concave and desired shaped rim, overlaying the design cutout on the plurality of sheets, and applying high heat to the glass mold.