COMPOSITE MATERIALS AND RELATED METHODS FOR MANUFACTURING COMPOSITE MATERIALS

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.