Despite the many benefits of carbon fiber composites, such composites
are typically black and the carbon fibers are typically visible on the
composite surface. In addition, the fibers (either as a unidirectional, prepregwoven,
or nonwoven substrate) are typically variable in their construction and
therefore are variable in their surface presentation. As a result, the
resulting carbon fiber composite can have cosmetic imperfections that
reduce the aesthetic appearance of the molded article formed therefrom.
Further, carbon fiber composites, often being black, provide a narrow
range of surface appearance to the molded article and therefore may give
a "tired", carbon sheetsunexciting look.
From the summary:
A
composite laminate having an improved cosmetic surface is presented
herein. The composite laminate includes a plurality of sheets of
preimpregnated material, or prepreg, stacked one over another and a
scrim layer provided on an exterior surface of the sheets of prepreg.
The scrim layer and the sheets of prepreg form a composite laminate
whereby the scrim layer constitutes an outer, exposed surface of the
composite laminate. Each sheet of prepreg is made from fibers
preimpregnated with resin, and the fibers of the prepreg may be
substantially parallel or woven carbon fibers. The scrim layer may be a
glass fiber or carbon fiber scrim, or veil, that has absorbed resin from
the sheets of prepreg during a molding process. In another embodiment, carbon cloththe
composite laminate includes a plurality of sheets of prepreg stacked
one over another and first and second scrim layers provided on opposing
exterior surfaces of the sheets of prepreg, whereby the sheets of
prepreg are sandwiched between the first and second scrim layers. The
first and second scrim layers constitute exposed surfaces of the
composite laminate.
The first claim:
A composite laminate
comprising:a plurality of sheets of prepreg, the sheets being stacked
one over another, each sheet of prepreg including fibers preimpregnated
with resin;cc composite
anda scrim layer provided on an exterior surface of the plurality of
sheets of prepreg, wherein the scrim layer and the sheets of prepreg
form a composite laminate whereby the scrim layer constitutes an outer,
exposed surface of the composite laminate.
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