Fiber reinforced composite material and method of making same |
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| 申请号 | US18404471 | 申请日 | 1971-09-27 | 公开(公告)号 | US3889348A | 公开(公告)日 | 1975-06-17 |
| 申请人 | LEMELSON JEROME H; | 发明人 | LEMELSON JEROME H; | ||||
| 摘要 | An apparatus and method for producing a composite material and the composite structure are provided. The structure is a filament reinforced matrix which is produced by forming a matte of filaments, feeding a filler material to the matte and molding the composite to shape to provide a matrix reinforced with filaments which are substantially predeterminately disposed within the matrix. The apparatus includes, in one form, a recepticle for the matte and matrix material including aligned rollers between which the matte and filler material are fed and which shape and drive the material therebetween. | ||||||
| 权利要求 | 1. A METHOD OF FORMING A COMPOSITE ARTICLE COMPRISING: FORMING A COMPOSITE MIXTURE OF ELONGATED FILMANETS INTO A DISCRETE MATTE FORMATION OF SPACE-SEPARATED FILAMENTS DEFINING A PLURALITY OF LAYERS OF FILAMENTARY MATERIAL EACH THE INDIVIDUAL FILAMENTS GENERALLY ALIGNED WITHIN EACH LAYER WHEREIN SAID MATTE FORMATION DEFINES INTERSTICES BETWEEN ADJACENT FILAMENTS, DISPOSING SAID MATTE FORMATION IN THE CAVITY OF A MOLD, ADMITTING A MOLDING MATERIAL IN A MOLDABLE CONDITION TO SAID MOLD CAVITY AND CAUSING SAID MOLDING MATERIAL TO COMPLETELY FILL THE INTERSTICES BETWEEN THE FILAMENTS OF SAID MATTE FORMATION AND SAID MOLD, AND FORMING A SOLID COMPOSITE ARTICLE CAUSING SAID MOLDING MATERIAL TO FORM A SOLID MASS IN SITU BETWEEN THE FILAMENTS OF SAID MATTE FORMATION SO AS TO ENCAPSULATE SAID FILAMENTS WITHIN SAID SOLIDIFIED MOLDING MATERIAL. 2. A method in accordance with claim 1 including the further step of disposing a sheet material against a face of said matte formation prior to the molding operation and forming an integral composite assembly of said sheet material, said matte formation and said molding material by fusing said molding material in situ against said sheet material. 3. A method in accordance with claim 1 including the steps of compressing said matte within said mold and causing said molding material to be flowed during the compressing step throughout the interstices of said matte formation. 4. A method in accordance with claim 1 wherein said molding material is powdered metal caused to fill the interstices of said matte formation further including the step of compressing said matte formation and powdered metal in said mold to compact same, heating the compacted formation and sintering the particles into a matrix which is reinforced by said filaments. 5. A method in accordance with claim 4 wherein the compaction of the filaments and powdered metal and the heating and sintering of the metal is such as to provide a porous composite article which contains said filaments extending therethrough. 6. A method in accordance with claim 1 wherein said molding material is a powdered metal caused to fill the interstices of said matte formation, further including first compressing the matte formation and powdered metal in the mold and heating said material to render the powdered metal molten and further compressing the matte formaTion and molten metal, while solidifying the molten metal into a molding containing said matte of filaments integrally encapsulated therein. 7. A method in accordance with claim 1 wherein said molding material is heat fusible and settable in particulate form and is caused to fill the interstices of said matte formation, further including heating and compressing the material in the mold to fuse said particles together into a unitary mass about the filaments of said matte to form a unitary solid structure wherein said molding material encapsulates the filaments of said matte within said solidified filler material. 8. A method in accordance with claim 1 wherein said filaments are made of thermoplastic material, said method comprising continuously extrusuion forming and feeding said filaments between opposed belt conveyors and continuously feeding said molding material between said belt conveyors to form a sheet-like formation of said molding material reinforced with said filaments. 9. A METHOD OF FORMING A COMPOSITE MATERIAL COMPRISING: CONTINOUSLY FORMING A FIRST MATERIAL INTO A PLURALITY OF FILAMENTS AND FEEDING SAID FILAMENTS TO A MOVABLE FORMING MEANS, FLOWING A SECOND MATERIAL TO SAID MOVABLE FORMING MEANS AND CAUSING SAID SECOND MATERIAL TO SURROUND THE FILAMENTS BEING FED TO SAID MOVABLE FORMING MEANS SOLIDIFYING SAID SECOND MATERIAL AS IT IS OPERATED ON BY SAID MOVABLE FORMING MEANS TO FORM A COMPOSITE MATERIAL COMPOSED OF SAID FILAMENTS ENCAPSULATED WITHIN SAID SECOND MATERIAL. 10. A method in accordance with claim 9 wherein said plurality of filaments are extrusion formed and fed to said further forming means directly from an extruder. 11. A method in accordance with claim 9 wherein said first material is continuously formed into a sheet and said filaments are formed by slitting said sheet and then fed to said movable forming means. 12. A method in accordance with claim 9 wherein said forming means comprising a plurality of space separated rolls, feeding said filaments and said second material between said rolls, compressing said materials between said rolls to form said composite material thereof and driving said rolls to force said composite material therefrom. 13. A COMPOSITE STRUCTURE COMPRISING: A MATRIX FORMING THE MAJOR PORTION OF SAID STRUCTURE, FILAMENTARY MATERIAL DISPOSED WITHIN SAID MATRIX AS A PLURALITY OF LAYERS OF FILAMENTS HAVING A MATTE-LIKE CONFIGURATION WITH THE INDIVIDUAL FILAMENTS GENERALLY ALIGNED WITH EACH LAYER, SAID MATRIX BEING SELECTED FROM THE GROUP OF METALS INCLUDING ALUMINUM, MAGNESIUM, TITANIUM, TUNGSTEN, AND STEEL AND ALLOYS OF SUCH METALS, SAID FILAMENTARY MATERIAL BEING SELECTED FROM THE GROUP COMPRISING BORON, BORON NITRIDE, SILICON NITRIDE, SILICON CARBIDE, ALUMINUM OXIDE, TITANIUM CARBIDE, TUNGSTEN CARBIDE AND PYROLITIC GRAPHITE. |
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