Patent ID: 9427917
Filing Date: 2016-08-30
CPC Classification: B29B,B29C,B29K,B29L,B32B,Y10T

Claim Text:
1. An intermediate material, intended to be associated with a thermosetting resin for fabricating composite parts, said intermediate material having a first surface and a second surface, said intermediate material consisting of: a unidirectional layer of carbon fibers with a surface density of 100 to 280 g/m a first web which comprises nonwoven thermoplastic fibers that have diameters of from 0.5 microns to 16 microns, said first web having an interior side located next to the first side of said unidirectional layer of carbon fibers and an exterior side which forms the first surface of said intermediate material, wherein said first web is thermally bonded to the first side of said unidirectional layer of carbon fibers and wherein the distance between the interior side and exterior side of said first web is from 3 to 15 microns; a second web which comprises nonwoven thermoplastic fibers that have diameters of from 0.5 microns to 16 microns, said second web having an interior side located next to the second side of said unidirectional layer of carbon fibers and an exterior side which forms the second surface of said intermediate material, wherein said second web is thermally bonded to the second side of said unidirectional layer of carbon fibers and wherein the distance between the interior side and exterior side of said second web is from 3 to 15 microns; and a plurality of surfaces which define a plurality of holes wherein each of said holes has a perimeter and wherein each of said holes extends from the first surface of said intermediate material to the second surface of said inter material to thereby form a plurality of perforations through said intermediate material and wherein said thermal bonding of said first and second webs to said layer of unidirectional carbon fibers is provided only by spot thermal bonding welds that are in the form discontinuous lines of spot welds which extend across the first and second surfaces said intermediate material.