Abstract: An improved carbon fiber tape of an open weave construction is provided. The tape comprises a plurality of adjacent substantially parallel and spaced linear warp ends of a carbonaceous fibrous material containing at least 90 percent carbon by weight substantially coextensive with the length of the tape in absence of substantial lateral contact between adjacent warp ends, and a weft pick containing at least 90 percent carbon by weight interlaced with the warp ends in a plain weave construction at a frequency of about 2 to 8 picks per inch of tape with the weft pick being provided under a tension sufficient that the linear configuration of the warp ends is substantially unimpaired. The carbon fiber tape of the present invention may be utilized in the formation of pervious low density composite articles when impregnated with a thermosetting resinous matrix.

Abstract: The efficient production of pervious low density carbon fiber reinforced composite articles is made possible through the use of the present invention. A fibrous open weave tape (as described) which is capable of undergoing conversion to a carbonaceous fibrous material is continuously passed in the direction of its length through a series of heating zones to form a fibrous carbon tape (preferably of graphitic carbon) wherein an open weave construction is maintained. At least one layer of the resulting fibrous open weave carbon tape may be impregnated with a thermosetting resinous material, and subsequently cured to form a pervious composite article.The composite articles exhibit a high specific modulus and strength, and are extremely lightweight. The lightweight composite articles may be utilized as structural elements, and are particularly suited for use as a facing sheet of an acoustic sandwich liner which serves as a noise suppression function in jet engines.