Continuous filament mat binder system

A method for making a continuous filament mat, the method comprising the steps of:

• providing at least one continuous filament fiber;
• applying a sizing composition to each of said at least one continuous filament fibers;
• forming said at least one continuous filament fiber into a continuous fiber strand;
• applying a CFM binder to said continuous fiber strand, said CFM binder comprising a phenolic compatible silane and a powdered bisphenol epoxy powdered resin having a thermally active dicyandiamide cross-linking resin;
• and
• drying and curing said CFM binder on said continuous fiber strand;
• pressing said continuous fiber strand having said CFM binder to form the continuous filament mat.

A method for forming a pultruded composite part comprising the steps of:

• applying a sizing composition to at least one continuous filament fiber;
• forming said at least one continuous filament fiber into a continuous fiber strand;
• applying a CFM binder to said continuous fiber strand, said CFM binder comprising a phenolic compatible silane and a powdered bisphenol epoxy powdered resin having a thermally active dicyandiamide cross-linking resin;
• and
• drying and curing said CFM binder on said continuous fiber strand;
• pressing said continuous fiber strand having said CFM binder;
• slitting and chopping said continuous filament mat to a desired size and shape to form a continuous filament mat;
• pulling at least one of said continuous filament mats and at least one continuous filament roving through a phenolic resin bath;
• and
• molding and curing said continuous filament mat and said at least one continuous fiber roving within a heated pultrusion die to form the pultruded composite part.

A method for forming a epoxy prepreg comprising the steps of:

• providing at least one continuous filament fiber;
• applying a sizing composition to at least one continuous filament fiber;
• forming said at least one continuous filament fiber into a continuous fiber strand;
• applying a CFM binder to said continuous fiber strand, said CFM binder comprising a phenolic compatible silane and a powdered bisphenol epoxy powdered resin having a thermally active dicyandiamide cross-linking resin;
• drying and curing said CFM binder on said continuous fiber strand;
• pressing said continuous fiber strand having said CFM binder;
• slitting and chopping said continuous filament mat to a desired size and shape to form a continuous filament mat;
• pulling said continuous filament mat through a epoxy resin bath;
• prestaging said continuous filament mat having a quantity of said epoxy resin in an oven;
• and
• pressing said continuous filament mat having a quantity of epoxy resin to a predetermined thickness to form the epoxy prepreg.

A method for forming a pultruded composite part comprising the steps of:

• applying a sizing composition to at least one continuous filament fiber;
• forming said at least one continuous filament fiber into a continuous fiber strand;
• applying a CFM binder to said continuous fiber strand, said CFM binder comprising a phenolic compatible silane and a powdered bisphenol epoxy powdered resin having a thermally active dicyandiamide cross-linking resin;
• and
• drying and curing said CFM binder on said continuous fiber strand;
• pressing said continuous fiber strand having said CFM binder;
• slitting and chopping said continuous filament mat to a desired size and shape to form a continuous filament mat;
• pulling at least one of said continuous filament mats and at least one continuous filament roving through a urethane resin bath;
• and
• molding and curing said continuous filament mat and said at least one continuous fiber roving within a heated pultrusion die to form the pultruded composite part.