Spliced carbon fiber tow and splicing method

A method for forming a spliced carbon fiber tow, comprising:

• providing a first carbon fiber tow having a terminal end and a starting end, and a second carbon fiber tow having a terminal end and a starting end, the first and second carbon fiber tows each containing 3,000 or more carbon fiber filaments;
• cutting and removing a portion of the fiber filaments of the first carbon fiber tow to form a rarefied region that extends from the terminal end of the first carbon fiber tow to a first joint end;
• cutting and removing a portion of the fiber filaments of the second carbon fiber tow to form a rarefied region that extends from the starting end of the second carbon fiber tow to a second end joint;
• aligning the rarefied region of the first carbon fiber tow with the rarefied region of the second carbon fiber tow so that so that the starting end of the second carbon fiber tow substantially meets the joint end of the first carbon fiber tow, and the terminal end of the first carbon fiber tow substantially meets joint end of the second carbon fiber tow;
• and
• subjecting the aligned rarefied regions of the first carbon fiber tow and the second carbon fiber tow to gas turbulences to effect entanglement of the carbon fiber filaments of the first and second carbon fiber tows with each other so as to form a splice,
• wherein the density of the spliced carbon fiber tow is substantially uniform from the starting end of the first carbon fiber tow to the terminal end of the second carbon fiber tow.