THERMOPLASTIC CARBON FIBER LAMINATE WITH A RANDOMLY ORIENTED FIBER REINFORCED CORE LAYER
A thermoplastic carbon fiber laminate with a randomly oriented fiber reinforced core layer provides a low cost, low weight, and high stiffness material for mechanical panels used in portable information handling systems.
1 . A carbon fiber composite material, comprising:
a first outer layer further comprising a first thermoplastic matrix reinforced with first directional carbon fiber;
a core layer bonded to the first outer layer, the core layer further comprising a second thermoplastic matrix reinforced with non-woven carbon fiber; and
a second outer layer bonded to the core layer, the second outer layer further comprising a third thermoplastic matrix reinforced with second directional carbon fiber,
wherein at least one of the first thermoplastic matrix, the second thermoplastic matrix, and the third thermoplastic matrix comprises polysulfonate.
2 . The carbon fiber composite material of claim 1 , wherein the first directional carbon fiber and the second directional carbon fiber consist of a continuous carbon fiber weave.
3 . The carbon fiber composite material of claim 1 , wherein the first directional carbon fiber and the second directional carbon fiber consist of continuous unidirectional carbon fiber.
4 . The carbon fiber composite material of claim 1 , wherein the non-woven carbon fiber comprises discrete carbon fiber with random orientation.
5 . The carbon fiber composite material of claim 1 , wherein the non-woven carbon fiber comprises recycled carbon fiber.
6 . The carbon fiber composite material of claim 1 , wherein the first thermoplastic matrix, the second thermoplastic matrix, and the third thermoplastic matrix consist of the same material.
7 . The carbon fiber composite material of claim 1 , wherein the first thermoplastic matrix, the second thermoplastic matrix, and the third thermoplastic matrix comprise the same material.
8 . The carbon fiber composite material of claim 1 , wherein the first thermoplastic matrix is thermally bonded to the second thermoplastic matrix, and the third thermoplastic matrix is thermally bonded to the second thermoplastic matrix.
9 . A mechanical panel for use in portable information handling systems, the mechanical panel comprising:
a first outer layer further comprising a first thermoplastic matrix reinforced with a first directional carbon fiber layer;
a core layer bonded to the first outer layer, the core layer further comprising a second thermoplastic matrix reinforced with a non-woven carbon fiber layer; and
a second outer layer bonded to the core layer, the second outer layer further comprising a third thermoplastic matrix reinforced with a second directional carbon fiber layer,
wherein at least one of the first thermoplastic matrix, the second thermoplastic matrix, and the third thermoplastic matrix comprises polysulfonate.
10 . The mechanical panel of claim 9 , wherein the first directional carbon fiber layer and the second directional carbon fiber layer consist of a continuous carbon fiber weave.
11 . The mechanical panel of claim 9 , wherein the first directional carbon fiber layer and the second directional carbon fiber layer consist of continuous unidirectional carbon fiber.
12 . The mechanical panel of claim 9 , wherein the non-woven carbon fiber layer comprises discrete carbon fiber with random orientation.
13 . The mechanical panel of claim 9 , wherein the non-woven carbon fiber layer comprises recycled carbon fiber.
14 . The mechanical panel of claim 9 , wherein the first thermoplastic matrix, the second thermoplastic matrix, and the third thermoplastic matrix consist of the same material.
15 . The mechanical panel of claim 9 , wherein the first thermoplastic matrix, the second thermoplastic matrix, and the third thermoplastic matrix comprise the same material.
16 . The mechanical panel of claim 9 , wherein the first thermoplastic matrix is thermally bonded to the second thermoplastic matrix, and the third thermoplastic matrix is thermally bonded to the second thermoplastic matrix.