Innovative Production of Composites with Through Plane Alignment of Fi-bers

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Short-fiber composites (SFC) rely on the exceptional properties of the reinforcing fiber phase to enhance the properties of the matrix. Depending on the product application required, the fibers must be arranged in a particular orientation, either in-plane, through-plane, etc. Due to cost and mass-production concerns, through-plane fiber orientation is usually not pursued. This proposal seeks to develop composites with through-plane aligned (TPA) fibers, as they can significantly improve properties of SFCs for use in a number of existing applications. Moreover, many new and innovative applications can be envisaged if through-plane alignment of fibers can be properly controlled. The most common way of controlling the in-plane alignments is by applying a shear flow field, which can be inherently generated in extrusion or injection molding processes. Aligning fibers perpendicular to the plane (through-plane) is more difficult because of the challenges in controlling the shear flow field. Many techniques are based on utilizing electromagnetic forces on particles in fluid suspensions and then solidification. Mechanical methods are not suitable for large scale production. Possible applications include electrically and thermally conductive coatings, wear resistant surfaces, permeable membranes, heat sinks, and innovative sensors etc.