Methods of Molding Non-Woven Carbon Fiber Mats and Related Molded Products

摘要

Methods for making a molded non-woven carbon fiber containing mat are provided, along with the resulting mats. Furthermore, methods are generally provided for using the molded non-woven carbon fiber containing mat to form a molded product, along with the resulting molded products.

主权项

1. A method of making a molded non-woven carbon fiber containing mat, the method comprising:
mixing an aqueous slurry comprising carbon fibers and binder fibers, wherein the aqueous slurry comprises the binder fibers in an amount of about 1% to about 10% by weight based on the weight of the slurry, and wherein the binder fibers comprising non-adhesive thermoplastic multi-component fibers; depositing the slurry onto a porous forming surface to form a wet-laid mat supported by the porous forming surface; removing water from the wet-laid mat through the porous forming surface; activating the binder fibers such that the binder fibers form a melt attachment to the carbon fibers; and further drying the wet-laid mat to form a non-woven carbon fiber mat having an open network of carbon fibers.