Low density cloth preform and methods of manufacturing same

Abstract

The disclosure describes a low density cloth preform, and apparatuses and methods for manufacturing the same. The low density cloth preform has a lower density than other preforms manufactured using prior apparatuses and methods, thereby rendering the low density cloth preform more amenable to the addition of matrix carbon thereto through the use of less expensive carbon sources and more rapid processes for adding matrix carbon. The apparatuses and methods for manufacturing the low density cloth preform comprise preform needling machines configured and preform needling processes operable to provide a more uniform and lesser needling depth with the result being a preform having a lower density. The preform needling machines utilize foam bases formed from resilient materials having appropriate rebound rates, arrangements of barbed needles in one or more groups and needling stages, and positioning of the barbed needles to minimize deflection of the foam bases and preform material.