​​Carbon Fiber Surface Mat Surface Treatment Interlaminar Bonding​​

​​1. Product Introduction​​

Carbon Fiber Surface Mat is a non-woven carbon fiber material engineered from short-cut carbon fibers via wet-lay forming and vacuum consolidation. It features uniform fiber distribution, smooth surface texture, and exceptional permeability, making it ideal for enhancing composite materials. Key attributes:

• ​​Lightweight​​: Density as low as 1.5–2.0 g/cm³, ideal for aerospace and automotive applications.

• ​​High Strength-to-Weight Ratio​​: Tensile strength up to 4,800 MPa, outperforming traditional glass fiber.

• ​​Electrical Conductivity​​: Surface resistivity <10 Ω, suitable for EMI shielding and electronic components.

• ​​Chemical Resistance​​: Resists acids, alkalis, and solvents, ensuring durability in harsh environments.

• ​​Applications​​: Automotive panels, aerospace interiors, electronic housings, wind turbine blades, and sports equipment.

​​2. Manufacturing Process​​

1. ​​Precursor Processing​​:

   • PAN-based carbon fiber precursor is stabilized at 200–300°C and carbonized at 1,000–3,000°C to achieve graphite-like structure

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2. ​​Fiber Cutting & Dispersion​​:

   • Carbon fibers (6–7 µm diameter) are cut into 30–50 mm lengths and dispersed in water with eco-friendly binders

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3. ​​Wet-Lay Forming​​:

   • Fibers are layered on a mesh conveyor, vacuum-assisted to remove air, and pressed into uniform mats (30–50 g/m²)

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4. ​​Surface Treatment​​:

   • Coated with sizing agents (e.g., silane) to enhance adhesion and UV resistance

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5. ​​Quality Control​​:

   • ISO 9001-certified testing for tensile strength, surface resistivity, and thickness consistency

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​​3. Usage Precautions​​

• ​​Handling​​:

  • Avoid sharp tools to prevent fiber breakage; wear PPE (gloves, goggles) during cutting.

• ​​Resin Compatibility​​:

  • Ensure compatibility with epoxy, polyester, or vinyl ester resins for optimal bonding.

• ​​Curing Conditions​​:

  • Maintain 120–150°C and 0.5–1.0 MPa pressure in autoclaves to eliminate voids

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• ​​Storage​​:

  • Store in dry, ventilated areas; avoid humidity to prevent delamination.

​​4. Specifications​

​​5. Applications & Case Studies​​

​​A. Automotive​​

• ​​Body Panels​​: Lightweight panels for EVs (e.g., BMW i3) to reduce weight by 30–50%

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• ​​Interior Trim​​: Noise-damping panels for luxury vehicles.

  • Case: Tesla Model S door panels using carbon fiber mats for weight reduction.

​​B. Aerospace​​

• ​​Aircraft Interiors​​: Fire-resistant seat covers and overhead bins

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• ​​Rocket Components​​: Lightweight fuel tanks and structural parts.

  • Case: SpaceX Falcon 9 nose cones reinforced with carbon fiber mats.

​​C. Electronics​​

• ​​EMI Shielding​​: Enclosures for circuit boards and sensors

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• ​​Heat Sinks​​: Thermal management in smartphones and laptops.

  • Case: Samsung Galaxy S23 Ultra backplate for electromagnetic protection.

​​D. Wind Energy​​

• ​​Turbine Blades​​: Reinforcement for leading edges to withstand high winds

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​​E. Sports & Safety​​

• ​​Protective Gear​​: Helmets and cycling frames (e.g., Trek Emonda SLR).