Manufacturing Apparatus And Method Of Forming A Preform

A method of forming a ceramic preform comprising ceramic particles and ceramic fibers having an aspect ratio of greater than or equal to 10:1 and the ceramic fibers substantially randomly orientated in three dimensions utilizing a mandrel and an extruder, said method comprising the steps of:

• extruding the ceramic particles and the ceramic fibers through the extruder to form an extrudate having a first end and a second end;
• forming the first end of the extrudate;
• wrapping the extrudate about the mandrel to form a first layer having the first end abutting the mandrel;
• applying pressure to the first layer during wrapping of the extrudate about the mandrel;
• forming the second end of the extrudate complementary in configuration to the first end;
• wrapping the extrudate about the mandrel to form a second layer on top of the first layer with the second end spaced from the mandrel;
• applying pressure to the second layer during wrapping of the extrudate about the mandrel;
• and
• aligning the second end complementary to the first end of the first layer in a spaced relationship to define the preform having a substantially uniform exterior surface and a substantially uniform thickness.

A manufacturing apparatus for forming a ceramic preform from an extrudate having a first end and a second end, said apparatus comprising:

• a multi-screw extruder including at least three intermeshing screws for forming the extrudate;
• a mandrel defining an outer diameter for wrapping the extrudate about said outer diameter to define a plurality of layers disposed on top of each other such that the extrudate defines an inner diameter complementary to said outer diameter of said mandrel;
• a pressure-applying device adjacent said mandrel for applying pressure to the layers of the extrudate;
• and
• a cutter for forming the first and second ends of the extrudate complementary to each other such that the first and second ends of the extrudate align with each other in a spaced relationship to define a preform having a substantially uniform exterior surface and a substantially uniform thickness.