Pre-impregnated composite material

Abstract

A pre-impregnated composite material comprises structural fibres that are attached to each other in the form of a thread, the structural fibres being impregnated with resin. The pre-impregnated composite material further comprises a boundary layer that encloses circumference of the thread. The boundary layer is adhered to the circumference of the thread for reinforcement.

What is claimed is: 
     
         1 - 20 . (canceled) 
     
     
         21 . A pre-impregnated composite material comprising:
 structural fibres that are attached to each other in the form of a thread, the structural fibres being impregnated with resin; and   a boundary layer that encloses a circumference of the thread,   wherein the boundary layer is adhered to the circumference of the thread for reinforcement, and   wherein the boundary layer comprises functional fibres that are adjoined to each other in forming a sleeve enclosing the structural fibres.   
     
     
         22 . The pre-impregnated composite material of  claim 21  further comprising:
 a plurality of longitudinal threads; and 
 a plurality of lateral threads that are weaved with the plurality of longitudinal threads in forming a sheet. 
 
     
     
         23 . The pre-impregnated composite material of  claim 21 , wherein the boundary layer further comprises an interface layer that encloses the functional fibres, the structural fibres or both. 
     
     
         24 . The pre-impregnated composite material of  claim 21 , wherein the structural fibres, the functional fibres or both comprise paper fibres. 
     
     
         25 . The pre-impregnated composite material of  claim 24 , wherein the paper fibres comprise wound paper cords. 
     
     
         26 . The pre-impregnated composite material of  claim 21 , wherein the structural fibres, the functional fibres or both comprise a fibre reinforcing core. 
     
     
         27 . The pre-impregnated composite material of  claim 21  further comprising a surface layer that encloses the boundary layer for covering. 
     
     
         28 . The pre-impregnated composite material of  claim 21 , wherein the boundary layer comprises undulation on its external surface for improving adhesion. 
     
     
         29 . The pre-impregnated composite material of  claim 28 , wherein the undulation comprises protrusions, fibrous bulges, flakes, films, coatings, fibrous strata, impregnated layers, rough areas, valleys, crevice or a combination of any number of these. 
     
     
         30 . The pre-impregnated composite material of  claim 21 , wherein the resin comprises thermosetting resin, epoxy resin, hybrid resin, thermoplastic resin, gel or a combination of any of these substances. 
     
     
         31 . The pre-impregnated composite material of  claim 21 , wherein the structural fibres, the functional fibres or both comprise natural fibres, man-made fibres, or a combination of both. 
     
     
         32 . The pre-impregnated composite material of  claim 31 , wherein the natural fibres comprise vegetable fibres, wood fibres, animal fibres, metal fibres or a combination of any number of these. 
     
     
         33 . The pre-impregnated composite material of  claim 31 , wherein the man-made fibres comprise semi-synthetic fibres, cellulose regenerated fibres, synthetic fibres or a combination of any number of these. 
     
     
         34 . The pre-impregnated composite material of  claim 21 ,
 wherein said pre-impregnated composite material is a knitted material, a laid material, a fleece or a woven material, with linen binding including warp threads or filling threads configured as threads which form a monofilament composite including the plurality of individual filaments and the non-crosslinked resin, and   wherein the individual filaments of all the threads are aligned in a same direction.   
     
     
         35 . The pre-impregnated composite material of  claim 21 ,
 wherein said pre-impregnated composite material is a sandwich material including at least one layer comprising a knitted material, a laid material and at least one layer including a fleece,   wherein the knitted material, the laid material or the woven material only includes the threads which include a plurality of individual filaments and the non-crosslinked resin and the fleece is provided with a non-crosslinked resin, and   wherein the layers are connected through bridges including the resin between adjacent threads or fibres of adjacent layers to form the pre-impregnated composite material.   
     
     
         36 . The pre-impregnated composite material of  claim 21 , wherein the structural fibres, the functional fibres or both are twisted. 
     
     
         37 . A method for producing a pre-impregnated composite material including fibres and a resin connecting the fibers, the method comprising the steps of:
 using threads which respectively include a monofilament composite including a plurality of functional fibres which are held together through a resin that is crosslinkable under an impact of at least one physical variable or a chemical substance, wherein the plurality of functional fibres are respectively aligned in a same direction;   forming the pre-impregnated composite material from the plurality of functional fibres in that the adjacent functional fibres threads are connected with one another at contact surfaces of their outer enveloping surfaces through bridges of the resin provided in non-crosslinked condition, the resin forming the bridges previously formed a portion of the plurality of functional fibres;   enclosing the plurality of functional fibres with functional fibres in forming a sleeve; and   enclosing the outer enveloping surfaces of the threads by a boundary layer.