Patent ID: 7198739

Claim:
A method of making multi-layer composite preform having a desired shape and a thickness in the range 0.25 to 7.5 inches and comprising multiple layers of fibrous mats wherein each of said fibrous mats comprises a random carbon-containing fibrous body within which is distributed a polymeric binder and wherein adjacent mat layers are bound together by additional polymer binder, stitching, and interlocking tabs, which method comprises the steps of: a.) providing a tool for shaping a fibrous mat layer, said tool including a perforated screen through which a vacuum can be drawn, wherein said tool is reconfigurable such that differently shaped composite preforms can be manufactured in the tool, b.) configuring said tool to provide said desired shape, c.) delivering chopped fiber tow to said configured tool while drawing vacuum therethrough, to form a fibrous object having said desired shape, d.) delivering binder to said fibrous object, e.) melting or curing said binder to make a fibrous mat, f.) assembling a plurality of said fibrous mats and additional binder into said preform having said desired shape for a carbon-carbon composite part in the substantial absence of cutting or other mechanical modification, and g.) heat-pressing the resulting mat assembly into a finished preform.