Uniaxial fibrous broadgoods for resin-matrix composite materials by electro-spinning

We propose to develop a process for producing resin-infusible unidirectional fiber broadgoods by electro-spinning an ultrafine non-woven fibrous mesh of polymeric material onto unidirectionally oriented fiber tows. The result will be a uniaxial fiber mat with good draping property and stability during cutting and handling, for use in composite laminate construction. The fabric can be made from any engineering fiber including carbon, glass, and ceramic and is suitable for various matrix infiltration processes. The electrospun mesh can be fabricated from a selection of polymers, enabling compatibility with any given epoxy system. The mesh will serve to maintain the integrity of the unidirectional fiber fabric during handling, as well as act as a light adhesive between fabric layers during the lay-up and molding process, allowing the elimination of stitching. Furthermore, it can be used in thermoplastic composites where the electrospun mesh will serve as the matrix material.