Patent ID: 9062417
Filing Date: 2015-06-23
Classification: B29B,B29C,B29K,D04H,D21H

Abstract:
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 a surface component of the binder fibers forms a melt attachment directly to the carbon fibers; further drying the wet-laid mat to form a non-woven carbon fiber mat having an open network of carbon fibers; impregnating the dried, non-woven carbon fiber mat with a resin; and subjecting the impregnated non-woven carbon fiber mat to vacuum assisted resin transfer conditions in a mold to cause mold flow and re-melt the surface component of the binder fiber to form the molded non-woven carbon fiber containing mat.