Thermoplastic Bonded Preforms and Thermoset Matrices Formed Therewith

Abstract

A thermoplastic bonded preform and method of manufacturing the preform are disclosed. The preform comprises a primary fiber comprising little or no sizing; a mechanical fiber; and a thermoplastic.

1 . A thermoplastic bonded preform comprising:
 a primary fiber comprising little or no sizing;   a mechanical fiber; and   a thermoplastic.   
     
     
         2 . The thermoplastic bonded preform of  claim 1  wherein said thermoplastic bonded preform has a density of 0.25 to 1 g/cm 3 . 
     
     
         3 . The thermoplastic bonded preform of  claim 1  wherein said primary fiber is a carbon fiber. 
     
     
         4 . The thermoplastic bonded preform of  claim 3  wherein said carbon fiber is selected from a recycled carbon fiber and a virgin carbon fiber. 
     
     
         5 . The thermoplastic bonded preform of  claim 1  wherein said primary fiber has a length of <5 cm. 
     
     
         6 . The thermoplastic bonded preform of  claim 5  wherein said primary fiber has a length of 0.508 cm to 1.78 cm. 
     
     
         7 . The thermoplastic bonded preform of  claim 1  wherein said primary fiber has a diameter of between 5 and about 9 μm. 
     
     
         8 . The thermoplastic bonded preform of  claim 1  wherein said primary fiber has a stiffness of at least 30 Mpsi. 
     
     
         9 . The thermoplastic bonded preform of  claim 1  wherein said mechanical fiber is a fibrillated fiber. 
     
     
         10 . The thermoplastic bonded preform of  claim 1  wherein said mechanical fiber is selected from the group consisting of cotton linter, cellulosic fiber, acrylic fiber and aramid fiber. 
     
     
         11 . The thermoplastic bonded preform of  claim 1  wherein said thermoplastic is selected from the group consisting of polyethylene, polypropylene, polyester, polyamide, polycarbonate, polyphenylene sulfide, polysulfone, polyetherimide, polyether ether ketone, poly ether ketone ketone, and blends thereof. 
     
     
         12 . The thermoplastic bonded preform of  claim 11  wherein said thermoplastic is selected from the group consisting of polypropylene, polyethylene terephthalate, polybutylene terephthalate, nylon 6, nylon 66, polycarbonate, polyphenylene sulfide, polyethersulfone and polyphenylsulfone. 
     
     
         13 . A composite comprising said thermoplastic bonded preform of  claim 1  infused with a resin. 
     
     
         14 . The composite of  claim 13  wherein said resin is a thermoset resin. 
     
     
         15 . The composite of  claim 14  wherein said resin is selected from the group consisting of epoxy, acrylic resin, polyester, vinyl ester, epoxy, polyurethane, furan, and bis-maleimides. 
     
     
         16 - 35 . (canceled)