US 12,006,605 B2
Non-woven micro-trellis fabrics and composite or hybrid-composite materials reinforced therewith
Joseph Pegna, Saratoga Springs, NY (US); Shay L. Harrison, East Schodack, NY (US); Erik G. Vaaler, Redwood City, CA (US); and John L. Schneiter, Cohoes, NY (US)
Assigned to Free Form Fibers, LLC, Saratoga Springs, NY (US)
Filed by FREE FORM FIBERS, LLC, Saratoga Springs, NY (US)
Filed on Jul. 24, 2020, as Appl. No. 16/938,072.
Claims priority of provisional application 62/905,598, filed on Sep. 25, 2019.
Prior Publication US 2021/0087726 A1, Mar. 25, 2021
Int. Cl. D04H 1/74 (2006.01); D04H 1/4234 (2012.01); D04H 1/4374 (2012.01); D04H 1/4382 (2012.01)
CPC D04H 1/74 (2013.01) [D04H 1/4234 (2013.01); D04H 1/4374 (2013.01); D04H 1/43835 (2020.05); D10B 2403/033 (2013.01)] 4 Claims
OG exemplary drawing
 
1. A structure comprising:
a non-woven fabric, the non-woven fabric including a three-dimensional array of fibers comprising:
a fiber forest comprising a two-dimensional array of standing fibers of equal height extending within the non-woven fabric perpendicular to a surface of the non-woven fabric;
multiple layers of non-woven discrete fibers within the non-woven fabric running parallel to the surface of the non-woven fabric in between the array of standing fibers in a defined pattern of fiber layer orientations, wherein fibers of the multiple layers of non-woven discrete fibers running parallel to the surface of the non-woven fabric are laser chemical vapor deposition (LCVD) formed fibers; and
wherein standing fibers of the array of standing fibers of equal height extending perpendicular to the surface of the non-woven fabric are anchored into a metal base substrate, and form a hybrid-composite with the metal base substrate integrally joined by the standing fibers to a composite material structure comprising a matrix material surrounding the multiple layers of non-woven discrete fibers within the non-woven fabric.