Oriented chopped fiber mats and method and apparatus for making same
First Claim
1. A process of manufacturing a nonwoven mat from electrically nonconductive fiber feedstock, comprising the steps of:
- increasing the conductivity of said feedstock by condensation of a gas containing electrical conductive material on the fiber feedstock to form treated fibers that are conductive;
chopping said feedstock into fibers of a predetermined length;
causing said treated fibers to fall under the influence of gravity through a directional electric field of sufficient strength to orient the fibers substantially parallel to a predetermined orientation axis;
collecting said oriented fibers on a transfer surface to create an oriented, nonwoven mat; and
causing an electric current to flow within said mat on said transfer surface to produce a directional electric field immediately above said mat substantially parallel to the desired orientation.
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Accused Products
Abstract
Apparatus for the manufacture of oriented chopped glass fiber mats from non-conductive fiber feed stock is disclosed. Apparatus includes means for increasing the conductance of the feed stock, electrically insulative transfer surface; means for establishing and maintaining a directional electric field to orient the chopped fibers, and a mat receiving surface to receive the oriented mat. The non-woven mat comprises a plurality of cut or chopped fibers having their longitudinal axes predominately disposed approximately parallel to a predetermined orientation axis lying in the plane of the mat. A preferred embodiment includes the incorporation of a glass fiber mat into a composite by applying a matrix resin to the mat in sufficient quantity to ensure the integrity of the composite. The process for manufacturing said non-woven oriented mats is also disclosed.
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Citations
17 Claims
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1. A process of manufacturing a nonwoven mat from electrically nonconductive fiber feedstock, comprising the steps of:
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increasing the conductivity of said feedstock by condensation of a gas containing electrical conductive material on the fiber feedstock to form treated fibers that are conductive; chopping said feedstock into fibers of a predetermined length; causing said treated fibers to fall under the influence of gravity through a directional electric field of sufficient strength to orient the fibers substantially parallel to a predetermined orientation axis; collecting said oriented fibers on a transfer surface to create an oriented, nonwoven mat; and causing an electric current to flow within said mat on said transfer surface to produce a directional electric field immediately above said mat substantially parallel to the desired orientation. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A process of manufacturing a nonwoven mat from the electrically nonconductive fiber feedstock, comprising the steps of:
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increasing the conductivity of said feedstock by treating the fiber feedstock with electrical conductive material which includes an antistatic compound; chopping said feedstock into fibers of a predetermined length; causing said treated fibers to fall under the influence of gravity through a directional electric field of sufficient strength to orient the fibers substantially parallel to a predetermined orientation axis; collecting said oriented fibers on a transfer surface to create an oriented, nonwoven mat; and causing an electric current to flow within said mat on said transfer surface to produce a directional electric field immediately above said mat substantially parallel to the desired orientation. - View Dependent Claims (16)
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17. A process of manufacturing a nonwoven mat from electrically nonconductive glass fiber feedstock, comprising the steps of:
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increasing the conductivity of said feedstock by condensation of moisture on the glass fiber feedstock to form a treated feedstock that is conductive; chopping said feedstock into fibers of a predetermined length; causing said treated fibers to fall under the influence of gravity through a directional electric field of sufficient strength to orient the fibers substantially parallel to a predetermined orientation axis; collecting said oriented fibers on a transfer surface to create an oriented, nonwoven mat; and causing an electric current to flow within said mat on said transfer surface to produce a directional electric field immediately above said mat substantially parallel to the desired orientation.
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Specification