METHOD FOR CONSOLIDATION FOR RANDOM CARBON FIBER ORIENTATION AND FOR FORMING A CARBON FIBER PREFORM

摘要

The present invention is a method of forming a composite including a carbon fiber layer surrounded by at least a single layer of non-woven fibers both above and below the carbon fiber layer. The layer(s) of carbon fiber and the layers of non-woven fibers are consolidated with a unique needle-punching method. According to another aspect of the invention, the layer(s) of carbon fiber and the layers of non-woven fibers are consolidated with a stitching method. The present invention also provides a method of forming a preform part, comprising a number of steps. First, arrangement of carbon fibers is coated with a binder, which is either a liquid or dry adhesive. Next, the carbon fiber arrangement is placed on a forming surface. The forming surface can be either a curved or generally flat surface. Third, pressure is applied to the carbon fiber arrangement. A vacuum bag or portions of a conventional mold can be used to apply pressure to the arrangement. Lastly, heat is applied to the carbon fiber arrangement to set the binder. Heat can be applied in a number of ways, including applying an electric current to the carbon fibers to resistively heat the carbon fiber arrangement. Once a sufficient quantity of heat has been applied to set the binder, the resulting preform part is allowed to cool and then removed from the forming surface. The preform part is then ready to be injected with resin and used with a mold to form a finished part.