A composite carbon fiber material is formed of one or more layers of carbon fiber
material in which the carbon fibers are aligned all in the same direction and a
mat of nonwoven, woven, or off-axis unidirectional carbon fibers are laminated
together. Layers may be used individually or as a hybrid. The layers can be preimpregnated
or impregnated during processing using thermoplastic or thermosetting resins. A
layer of thermoplastic resin is applied either over the surface or within the composite
structure, and the resin permeates the material so as to provide a more stable
mechanical structure once the resin is processed. The material combines good mechanical
strength with improved electrical current carrying properties when compared with
the aligned carbon fiber layer alone. The layering sequence, layer type, and resin
type can be specified to tailor electrical properties, mechanical properties, durability,
and wear resistance. The resultant material achieves these results in substantially
smaller material thickness than previously available.