STRUCTURED FLOCK FIBER REINFORCED LAYER

摘要

Various embodiments of structured flock fiber reinforced layers include fibrous organic polymer composite reinforcing materials that have been “pre-flocked” with Z-Axis reinforcing fibers. These “pre-flocked” fibrous materials (woven, knitted, mat, nonwoven or pre-pregs) are then supplied as “off-the-shelf,” “ready-to-use,” already flock reinforced, dry to the touch, pre-manufactured, storable, inventoried organic polymer composite structured flock fiber reinforced layers that are ready as needed to be laid-up and impregnated with matrix resin and cured to form fiber based z-directional reinforced composites having enhanced inter-laminar strength, impact toughness, transmission properties (electrical and thermal conduction) and coefficient of thermal expansion are provided. Methods for forming such reinforced layers are also provided.

主权项

1. A structured flock fiber reinforced layer comprising:
a fibrous laminar base-ply substrate comprising a plurality of fabric yarns forming a plurality of interstices; a thin adhesive sizing layer disposed on the fibrous laminar base-ply substrate; a plurality of reinforcing flock fibers, a majority of which are oriented substantially perpendicular to a first surface of the fibrous laminar base-ply substrate, the substantially perpendicularly oriented reinforcing flock fibers being partially embedded in the plurality of interstices, wherein the plurality of reinforcing flock fibers are bonded to surfaces of the plurality of fabric yarns by the thin adhesive sizing layer for subsequent composite ply material assembly; and wherein the sized and flocked fibrous laminar base-ply substrate remains flexible to conform to contour layups.