Patent ID: 9707724
Date: 2017-07-18
CPC Classifications: B29B,B29C,D02J,D04H,Y10T

Claim:
1. A method for using tows incorporating a large number of fibers to form a composite part that has the quality of parts made with tows incorporating a small number of fibers, said method comprising: spreading the tows incorporating a large number of fibers to form a relatively flat and continuous unidirectional fabric; holding the continuous unidirectional fabric under tension to maintain the orientation and flatness; applying a melt-bondable fabric to both a bottom and a top of the continuous unidirectional fabric; passing the continuous unidirectional fabric including the melt-bondable fabric on the bottom and top of the continuous unidirectional fabric through an oven; consolidating the melt-bondable fabric and the continuous unidirectional fabric in the oven while under tension; slicing the melt-bonded, unidirectional fabric into a plurality of narrow fiber tows; forming at least one of weaves and braids from at least some of the plurality of narrow fiber tows produced from slicing the melt-bonded, unidirectional fabric, thereby forming a woven or braided preform, wherein the woven or braided preform is dry and configured for subsequent infusion with a matrix resin.