Composite materials and related methods for manufacturing composite materials

Abstract

The present disclosure relates to composites. One composite may include a resin and oxidized polyacrylonitrile fibers. The oxidized polyacrylonitrile fibers may be provided as a nonwoven fabric. An additional composite may include a resin and material scraps respectively including carbon fibers. The material scraps may be positioned to at least partially overlap one another and define a substantially continuous layer. The material scraps may be provided as a fabric and/or a plurality of loose fibers.

1 . A composite, comprising:
 a resin; and   a plurality of oxidized polyacrylonitrile fibers, wherein the oxidized polyacrylonitrile fibers are provided as a nonwoven fabric.   
     
     
         2 . The composite of  claim 1 , wherein the oxidized polyacrylonitrile fibers are provided as a wet-lay nonwoven fabric. 
     
     
         3 . The composite of  claim 1 , wherein the plurality of oxidized polyacrylonitrile fibers define an outer layer. 
     
     
         4 . A method for forming a composite, comprising:
 forming a plurality of oxidized polyacrylonitrile fibers into a nonwoven fabric;   positioning the nonwoven fabric and a resin in a mold; and   curing the resin in the mold.   
     
     
         5 . The method of  claim 4 , wherein forming the oxidized polyacrylonitrile fibers into the nonwoven fabric comprises forming the oxidized polyacrylonitrile fibers into a wet-lay nonwoven fabric, and
 wherein positioning the nonwoven fabric and the resin in the mold comprises positioning the wet-lay nonwoven fabric and the resin in the mold.   
     
     
         6 . The method of  claim 4 , wherein positioning the nonwoven fabric in the mold comprises forming an outer layer with the nonwoven fabric. 
     
     
         7 . A composite, comprising:
 a resin, and   a plurality of material scraps respectively comprising a plurality of carbon fibers, the material scraps being positioned to at least partially overlap one another and define a substantially continuous layer,   wherein the material scraps respectively comprising the carbon fibers are provided in at least one of the following forms:
 a fabric; and 
 a plurality of loose fibers. 
   
     
     
         8 . The composite of  claim 7 , further comprising a plurality of pre-impregnated carbon fiber chips defining a second substantially continuous layer. 
     
     
         9 . The composite of  claim 8 , wherein the second substantially continuous layer is an outer layer. 
     
     
         10 . The composite of  claim 7 , defining a shipping container panel, a countertop, or a storm barrier panel. 
     
     
         11 . The composite of  claim 7 , further comprising at least one of an aramid layer and a fiberglass layer. 
     
     
         12 . The composite of  claim 7 , wherein each of the carbon fibers define a length greater than about one inch. 
     
     
         13 . The composite of  claim 7 , wherein the material scraps respectively comprising the carbon fibers are provided as the fabric and as the loose fibers. 
     
     
         14 . A method for forming a composite, comprising:
 providing a resin;   providing a plurality of material scraps respectively comprising a plurality of carbon fibers, the material scraps being provided in at least one of the following forms:
 a fabric; and 
 a plurality of loose fibers; 
   positioning the material scraps in a mold such that the material scraps at least partially overlap one another and define a substantially continuous layer;   adding the resin to the material scraps; and   hardening the resin in the mold.   
     
     
         15 . The method of  claim 14 , further comprising:
 providing a plurality of pre-impregnated carbon fiber chips;   positioning the pre-impregnated carbon fiber chips in the mold such that the pre-impregnated carbon fiber chips at least partially overlap one another and define a second substantially continuous layer; and   adding the resin to the pre-impregnated carbon fiber chips.   
     
     
         16 . The method of  claim 15 , wherein positioning the pre-impregnated carbon fiber chips in the mold comprises positioning the pre-impregnated carbon fiber chips such that the second substantially continuous layer is an outer layer. 
     
     
         17 . The method of  claim 14 , further comprising positioning at least one of an aramid material and a fiberglass material in the mold to define a strengthening layer; and
 adding the resin to the strengthening layer.   
     
     
         18 . The method of  claim 14 , wherein providing the material scraps comprises retaining the material scraps in an initial size and shape associated with formation of the material scraps. 
     
     
         19 . The method of  claim 14 , wherein hardening the resin in the mold comprises forming a shipping container panel, a countertop, or a storm barrier panel. 
     
     
         20 . The method of  claim 14 , wherein providing the material scraps comprises providing the fabric and the loose fibers.