Components Molded With Moldable Carbon Fiber And Methods of Manufacturing Thereof
First Claim
1. A structural component comprising:
- a body defining at least one hollow region, wherein the body comprises a carbon fiber composite comprising a plurality of substantially aligned continuous carbon fibers defining a major axis and a second axis perpendicular to the major axis, wherein the plurality of substantially aligned continuous carbon fibers comprise a plurality of discrete termination points staggered with respect to the second axis.
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Abstract
In various aspects, the present disclosure provides a structural component. The structural component includes a body defining at least one hollow region. The body includes a carbon fiber composite including a plurality of substantially aligned continuous carbon fibers. The plurality of substantially aligned carbon fibers defines a major axis and a second axis perpendicular to the major axis. The plurality of substantially aligned continuous carbon fibers includes a plurality of discrete termination points staggered with respect to the second axis. Methods of making such structural components, including by blow molding and compression molding are also provided.
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Citations
20 Claims
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1. A structural component comprising:
a body defining at least one hollow region, wherein the body comprises a carbon fiber composite comprising a plurality of substantially aligned continuous carbon fibers defining a major axis and a second axis perpendicular to the major axis, wherein the plurality of substantially aligned continuous carbon fibers comprise a plurality of discrete termination points staggered with respect to the second axis. - View Dependent Claims (2, 3, 4)
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5. A method of producing a structural component, the method comprising:
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creating a molding material by placing a sheet of a first carbon precursor material between two sheets of a second carbon fiber precursor material, wherein the first carbon fiber precursor material and the second carbon fiber precursor material are distinct from one another, wherein at least one of the first carbon fiber precursor material or the second carbon fiber precursor material comprises a moldable carbon fiber precursor material comprising a plurality of substantially aligned continuous carbon fibers defining a major axis and a second axis perpendicular to the major axis, wherein the plurality of substantially aligned continuous carbon fibers comprise a plurality of discrete termination points staggered with respect to the second axis; and compression molding the molding material to form the structural component. - View Dependent Claims (6, 7, 8, 9)
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10. A method of producing a structural component having at least one interior cavity, the method comprising:
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placing a parison comprising a moldable carbon fiber precursor material disposed around a mandrel in a die, wherein the moldable carbon fiber precursor material comprises a polymer precursor and a plurality of substantially aligned continuous carbon fibers defining a major axis and a second axis perpendicular to the major axis, wherein the plurality of substantially aligned continuous carbon fibers comprise a plurality of discrete termination points staggered with respect to the second axis; blow molding the parison to create the structural component; and crosslinking or solidifying the polymer precursor to form the structural component. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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Specification