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CARBON SUPERCOMPOSITE ™
A Durable, Safe, and Unique Carbon Fiber Composite
BOSTONMATERIALS
A New Dimension of PerformanceBoston Materials offers composite component manufacturers
Carbon Supercomposite™, a drastically toughened carbon fiber
composite with enhanced Z-axis properties that exhibits signs
of plastic deformation before fracture.
This material-level solution is made by applying a coating
of Z-axis oriented, milled carbon fibers to standard
carbon fiber fabrics, forming a 3D prepreg with dense
interlaminar reinforcement. Boston Materials supplies Carbon
Supercomposite™ as prepregs that are compatible with
virtually all carbon fiber composite manufacturing methods.
Performance by Design Carbon Supercomposite™ was created to overcome
the shortcomings of traditional 2D composites with
a patented fiber reinforcement that delivers highly
differentiated functionality and performance.
Durability with Stiffness
This revolutionary material utilizes
advanced methods to toughen
composites without sacrificing
strength or stiffness. Milled fiber
reinforcement of the material’s
Z-axis increases toughness by 300%
and strength by 35% without any
detriment to stiffness.
Safety via Plastic Deformation
With Carbon Supercomposite™, failure
is preceded by signs of deformation
due to delamination pinning.
Unique Thermal and
Electrical Properties
Milled fibers increase the Z-axis
thermal and electrical conductivities.
This enables PAN-based carbon
fiber composites to match the
conductivity of more expensive
pitch-based alternatives.
300% Increase in Through-Thickness Thermal Conductivity
Compressive Strength
35% More Enhanced
Traditional Carbon
Fiber Compression
Compressive
Toughness
300% More Enhanced
2 Carbon Supercomposite™
How it Works: Z-Axis Milled Fiber Reinforcement
Carbon Supercomposite™ is formed by coating a standard carbon fiber fabric with milled carbon fibers. The milled
fibers are vertically oriented by using a proprietary process. These Z-axis milled fibers mechanically pin the layers
of a laminated composite together, drastically increasing the interlaminar fracture toughness. This patented
interlaminar toughening mechanism effectively distributes multi-axial loads throughout the entire composite.
Compression
The lack of toughness in
carbon fiber laminates
is exacerbated under
compression where planar
compressive forces manifest
as a combination of Mode I
and II loads. Reinforcing the
interlaminar region with Z-axis
milled fibers provides bulk
toughness of over 12 MJ/m3.
This demonstrates a 300%
enhancement over current
carbon fiber materials.
3Carbon Supercomposite™
A Better Material for Your Applications
Carbon Supercomposite™ brings new design
improvements and performance benefits to
your demanding materials applications.
Sporting Goods:
Protecting your users while elevating product performance is
the ultimate goal. Carbon Supercomposite™ is a powerful tool
that delivers a competitive edge with a new level of safety.
Oil and Gas:
Corrosive and abrasive environments make it challenging to deliver
components that resist wear over a longer lifespan. Integrating Carbon
Supercomposite™ in your products can provide a unique combination of
compressive strength and wear resistance.
Pressure Vessels:
Higher energy density requirements for Type IV and V pressure
vessels make repeatable production of durable carbon fiber
composites a concern. Carbon Supercomposite™ allows you to
simplify your designs and increase manufacturing productivity.
Marine:
Carbon Supercomposite™ withstands rolling and irregular
forces, even under constant exposure to weather conditions.
This makes it ideally suited for a wide range of marine
applications from battens and hydrofoils to fins and rudders.
Automotive:
Safety is the top priority for crash structures and battery
packs. The toughness of Carbon Supercomposite™ can
enable lightweight designs that can take a hit.
Wind Energy:
The future is trending towards super-sized wind turbine blades
to increase energy density and return on investment. Carbon
Supercomposite™ can enable this trend by simplifying the layup
process while providing tolerance to defects and damage.
Aerospace:
Durability of high-temperature, carbon composite (C-C)
components like carbon seals is a critical safety issue for
modern aircraft. Carbon Supercomposite™ can be used to
produce tougher and more shock resistant C-C materials.
Carbon Supercomposite™4
5Carbon Supercomposite™
Carbon Supercomposite™ Vs. Traditional 2D Carbon Fiber
Patented Three-Step Manufacturing Process
Carbon Supercomposite™ utilizes
an innovative, environmentally-
responsible manufacturing process
to provide new performance
benefits while keeping costs low.
STEP 1: FABRIC SELECTION
Select any crimp or non-crimp fabric.
STEP 2: Z-AXIS MILLED FIBER
Add a coating of milled carbon
fibers in vertical alignment.
STEP 3: RESIN
Apply customer preferred
resin system.
CARBON SUPERCOMPOSITE™
+ +X Y = XYZZ
3
SupercompositeTM
bending point
TRADITIONAL 2D CARBON FIBER
+ =X Y XY
3
Traditional breaking point
6 Carbon Supercomposite™
Out-of-the-Box Compatibility Means Faster Time-to-Market Carbon Supercomposite™ is compatible with all layup,
automated tape laying, and roll wrapping manufacturing
methods. Prepregs are available with standard 250°F
and 350°F cure epoxy resins; unique resins can be
produced upon request. Prepregs rolls are currently
available up to 12-inch wide and up to 50-yard lengths.
Our Applications Team will work with you to quickly
integrate Carbon Supercomposite™ into your
established designs and production processes to
decrease your technical risk and time-to-market.
Take Your Application to the Next Generation of Performance Carbon Supercomposite™ by Boston Materials offers
unique advantages and cost savings that makes you
more competitive and strengthens your bottom line. To
learn more about this technological advance in carbon
fiber and how we can help you incorporate it into your
durable, safer, and unique products – contact us.
Carbon Supercomposite™ 7
Boston Materials 23 Crosby Dr, Bedford, MA 01730
P: (617)-227-2422 E: [email protected] W: bostonmaterials.co
©2019 Boston Materials, Inc.
BOSTONMATERIALS