Abstract: The instant invention involves a process used in preparing fibrous tows which may be formed into polymeric plastic composites. The process involves the steps of (a) forming a carbon fiber tow; (b) forming a thermoplastic polymeric fiber tow; (c) intermixing the two tows; and (d) withdrawing the intermixed tow for further use.

Abstract: The instant invention involves a process used in preparing fibrous tows which may be formed into polymeric plastic composites. The process involves the steps of (a) forming a carbon fiber tow; (b) forming a thermoplastic polymeric fiber tow; (c) intermixing the two tows; and (d) withdrawing the intermixed tow for further use.

Abstract: A composite article is prepared by forming a continuous tow of continuous carbon fibers, forming a continuous tow of thermoplastic polymer fibers, uniformly and continuously spreading the thermoplastic polymer fibers to a selected width, uniformly and continuously spreading the carbon fiber tow to a width that is essentially the same as the selected width for the thermoplastic polymer fiber tow, intermixing the tows intimately, uniformly and continuously, in a relatively tension-free state, continuously withdrawing the intermixed tow and applying the tow to a mold and heating the tow.

Abstract: The instant invention involves a process used in preparing fibrous tows which may be formed into polymeric plastic composites. The process involves the steps of (a) forming a tow of strong filamentary materials; (b) forming a thermoplastic polymeric fiber; (c) intermixing the two tows; and (d) withdrawing the intermixed tow for further use.

Abstract: The instant invention involves a process used in preparing fibrous tows which may be formed into polymeric plastic composites. The process involves the steps of (a) forming a tow of strong filamentary materials; (b) forming a thermoplastic polymeric fiber; (c) intermixing the two tows; and (d) withdrawing the intermixed tow for further use.

Abstract: The instant invention involves a process for use in preparing tapes or rovings, which are formed from a thermoplastic material used to impregnate longitudinally extended bundles of carbon fibers. The process involves the steps of (a) gas spreading a tow of carbon fibers; (b) feeding the spread tow into a crosshead die; (c) impregnating the tow in the die with a thermoplastic polymer; (d) withdrawing the impregnated tow from the die; and (e) gas cooling the impregnated tow with a jet of air.The crosshead die useful in the instant invention includes a horizontally extended, carbon fiber bundle inlet channel, means for providing melted polymer under pressure to the die, means for dividing the polymeric material flowing into the die into an upper flow channel and a lower flow channel disposed above and below the moving carbon fiber bundle, means for applying the thermoplastic material from both the upper and lower channels to the fiber bundle, and means for withdrawing the resulting tape from the die.

Abstract: An improved fabric is provided comprised of fusible and infusible fibers. The fusible fibers comprise thermotropic liquid crystal polymers (i.e., polymers which are capable of forming an anisotropic melt phase). When the liquid crystal fibers are heated, they fuse to adjacent infusible fibers without any substantial loss of the orientation which was imparted to the same during melt extrusion. A fabric of enhanced strength and stiffness is thus formed in comparison to a fabric which employs conventional thermoplastic polymers which do not form an anisotropic melt phase.

Abstract: An improved polycarbonate sizing finish is provided comprised of a polycarbonate dissolved in a solvent mixture comprising N-methyl-2-pyrrolidone (NMP) and an alcohol having from 1 to 4 carbon atoms. The use of such a solvent mixture enables a relatively constant concentration of polycarbonate to be maintained, and consequently, enables a sized product fiber to be provided having a substantially uniform polycarbonate concentration thereon. In addition, the solvent may be readily and substantially completely removed from the sized fiber.

Abstract: An improved continuous hot gas surface modification process for carbon fibers is provided. The carbon fibers undergoing such processing are passed for a relatively brief residence time through a surface treatment zone to which continuously is fed nitrogen dioxide and air under conditions which have been found to produce a surprisingly effective surface modification. The resulting carbon fibers exhibit a significantly enhanced surface area and an improved ability to bond to a resinous matrix material while retaining a substantial portion of the tensile strength originally exhibited. When incorporated in a resinous matrix material, a fiber reinforced composite article of enhanced interlaminar shear strength is formed.

Abstract: The present invention is directed to carbon fibers which are coated on the surface with a sizing agent of either a polyisocyanate, such as polymethylene polyphenyl polyisocyanate, or a sorbitol polyglycidyl ether having a specifically defined total chlorine content and epoxide equivalent weight. The coated carbon fibers are employed to prepare carbon fiber composites wherein the matrix resin is a thermoplastic polyester such as poly(1,4-butylene terephthalate). The matrix resin of the composite exhibits improved bonding with the coated carbon fibers thereby imparting improved interlaminar shear strength to the composite.