Method for Insertion of Carbon Fiber Through the Thickness of Dense Dry Fiber Preform

Creation of a structural joint for a heat shield for extreme entry environments requires structural fibers penetrating through the thickness of the shield at joint locations. The structural fibers must be made of carbon to withstand extremely high temperatures, i.e. 2000 ºC. Carbon fibers, due to their relatively high modulus (stiffness), are easily damaged and broken when handled by a conventional sewing machine. Special coatings such as nylon are required to increase the durability of the fiber to enable its use in a sewing or tufting process.