Electromagnetic energy absorbing three dimensional flocked carbon fiber composite materials

Abstract

This disclosure relates to electromagnetic absorbing materials, and, more particularly, to a flocked carbon fiber composite material and methods for forming thereof. The flocked carbon fiber material comprises electrostatically applied carbon fibers, having a Z-plane component; electromagnetic modifiers; a substrate; a bonding agent; and an encapsulation agent. The method for forming said flocked carbon fiber composite material comprises preparing carbon fiber strands; separating carbon fiber strand clumps into carbon fiber strands; separating carbon fiber strands into carbon fibers; applying a bonding agent to a substrate; and electrostatically applying the carbon fibers to the substrate. The flocking device used to perform this method comprises an insulative section; a high voltage power source; a container attached to the insulative section; and a filtering section attached to the container.

1 . A flocked carbon fiber material, comprising:
 electrostatically applied carbon fibers, having a Z-plane component; and   electromagnetic modifiers, wherein the electromagnetic modifiers are applied to the carbon fibers.   
     
     
         2 . The flocked carbon fiber material of  claim 1 , further comprising:
 a substrate material.   
     
     
         3 . The flocked carbon fiber material of  claim 1 , further comprising:
 a bonding agent.   
     
     
         4 . The flocked carbon fiber material of  claim 1 , further comprising:
 an encapsulation agent, wherein the encapsulation agent is applied to the carbon fibers.   
     
     
         5 . The flocked carbon fiber material of  claim 1 , wherein the electromagnetic modifiers contain ferromagnetic particles. 
     
     
         6 . The flocked carbon fiber material of  claim 1 , wherein the electrostatically applied carbon fibers form a Z-plane. 
     
     
         7 . The flocked carbon fiber material of  claim 2 , wherein the substrate material comprises any one or more materials composed of metals, ceramics, celluloses, or resins or combinations thereof. 
     
     
         8 . The flocked carbon fiber material of  claim 3 , wherein the bonding agent comprises any one or more of the following: acrylic, epoxy, urethane, polyester, or latex. 
     
     
         9 . The flocked carbon fiber material of  claim 4 , wherein the encapsulation agent comprises any one or more of the following: thermoplastic or thermosetting resin polymer formulations. 
     
     
         10 . A flocking device, comprising:
 an insulative section;   a high voltage power source;   a container attached to the insulative section; and   a filtering section attached to the container.   
     
     
         11 . The flocking device of  claim 10 , wherein the insulative section comprises a handle. 
     
     
         12 . The flocking device of  claim 10 , wherein the high voltage power source comprises range of 2 kV to 100 kV. 
     
     
         13 . The flocking device of  claim 10 , wherein the filtering section is a screen. 
     
     
         14 . The flocking device of  claim 13 , wherein the screen has ¼″ to 1/16″ inch. 
     
     
         15 . A method to form flocked material, comprising:
 preparing carbon fiber strands;   separating carbon fiber strand clumps into carbon fiber strands;   separating carbon fiber strands into carbon fibers;   applying a bonding agent to a substrate; and   electrostatically applying the carbon fibers to the substrate.   
     
     
         16 . The method of  claim 15 , further comprising:
 curing the substrate and carbon fibers.   
     
     
         17 . The method of  claim 15 , further comprising:
 applying electromagnetic modifiers.   
     
     
         18 . The method of  claim 15 , further comprising:
 applying pile surface conditioning agents to the electromagnetic modifiers.   
     
     
         19 . The method of  claim 15 , further comprising:
 applying an encapsulation agent to the carbon fibers.   
     
     
         20 . The method of  claim 15 , further comprising:
 removing the substrate from the carbon fibers.