Carbon fiber pre-pregs and methods for manufacturing thereof
A carbon fiber, pre-impregnation technology, applied in the direction of carbon fiber, fiber processing, thin material processing, etc., can solve problems such as poor plasticity, lack of fluidity, and unsatisfactory surface appearance
Active Publication Date: 2018-01-23
GM GLOBAL TECH OPERATIONS LLC
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- Claims
- Application Information
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Problems solved by technology
This inflexibility and rigidity can lead to poor plasticity, making it difficult to form three-dimensional shapes from composites with continuous carbon fibers
Further, the lack of fluidity in the prepreg can lead to warping in the final composite product as well as problems with undesired surface appearance
Method used
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[0030] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those skilled in the art. Numerous specific details are set forth, such as examples of specific compositions, components, devices, and methods, in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
[0031]The terminology used herein is for describing particular exemplary embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" may be intended to include the plural forms as well, unless the context...
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Abstract
Methods and components produced from carbon fiber pre-impregnated composite precursor materials (pre-preg) having enhanced flowability and moldability are provided. Discontinuous cut regions are introduced into a pre-preg. A sheet of pre-preg may be contacted with a patterned surface having a plurality of non-contiguous staggered cutters, so that the contacting creates discontinuous cuts in the pre-preg. A plurality of staggered discontinuous cut regions are formed in the plurality of continuous carbon fibers that define a first plurality of carbon fibers having a first length and a second plurality of carbon fibers having a second distinct length. The patterned surface may be provided on a cutter device that is a roller or a plate having the non-contiguous staggered cutters formed or disposed thereon. The discontinuous cut regions that are formed in the pre-preg reduce stiffness and improve moldability / flowability when forming carbon fiber polymeric composites, while retaining high strength levels.
Description
technical field [0001] The present disclosure relates to methods for processing continuous carbon fibers for use in high strength polymer composite prepregs with improved moldability and reduced warpage in molded parts. Background technique [0002] The statements in this section provide background information related to the present disclosure which is not necessarily prior art. [0003] Carbon fibers are used as a lightweight reinforcing phase to make high-strength lightweight polymer composites. Carbon fibers may be continuous filaments that may be thousands of micrometers (μm) or millimeters (mm) in length. A group of continuous carbon fibers is usually classified as a bundle of continuous carbon fiber filaments. Carbon fiber "tows" are usually specified as filament quantities in the thousands (denoted by a K following the respective tow quantity). Alternatively, the carbon fiber bundles may be chopped or milled and thus formed into short carbon fiber segments (filamen...
Claims
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IPC IPC(8): B29C70/54B29C70/18B29C70/22B29L31/30
CPCC08J5/042Y10T428/24314B26D1/225C08J5/248B32B3/266D06H7/02D06M15/55D06M2101/40D10B2101/12D10B2505/02
Inventor H·G·起亚N·D·埃里森S·X·赵
Owner GM GLOBAL TECH OPERATIONS LLC