# US 2019/0168420 A1 · FIBER-REINFORCED METAL-, CERAMIC-, and METAL/CERAMIC-MATRIX COMPOSITE MATERIALS AND METHODS THEREFOR > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0168420 A1 - Document ID: US20190168420A1 - Status: Published application - Kind: A1 - Application number: 16/135,931 - Filed: 2018-09-19 - Published: 2019-06-06 - Earliest claimed: 2017-09-19 - Assignees: Arris Composites Inc. - Applicants: Arris Composites Inc. - Inventors: Riley REESE; Ethan ESCOWITZ - Web page: https://patentgrep.com/patent/US20190168420A1 ## CPC - C04B 35/80: Fibres, filaments, whiskers, platelets, or the like - B29B 15/122: {with a matrix in liquid form, e.g. as melt, solution or latex} - B29B 15/125: {by dipping} - B29B 15/127: {by spraying} - B29B 15/14: of filaments or wires - B29C 48/0011: {combined with compression moulding} - B29C 48/022: {characterised by the choice of material} - B29C 48/05: Filamentary, e.g. strands - C04B 35/488: Composites - C04B 35/62695: {Granulation or pelletising (devices for shaping artificial aggregates from ceramic mixtures B28B1/004)} - C04B 35/62855: {Refractory metal oxides} - C04B 35/62892: {with a coating layer consisting of particles} - C04B 35/63464: {Polycarbonates} - C04B 35/638: Removal thereof - C04B 35/82: Asbestos; Glass; Fused silica - C22C 47/06: by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element - C22C 47/14: by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments - C22C 49/00: Alloys containing metallic or non-metallic fibres or filaments - C22C 49/08: Iron group metals - C22C 49/14: characterised by the fibres or filaments - B29K 2105/10: {Cords, strands or rovings, e.g.} oriented {cords, strands or rovings} - B29K 2105/253: {Preform} - B29K 2307/04: Carbon - B29K 2505/00: Use of metals, their alloys or their compounds, as filler - B29K 2509/02: Ceramics - C04B 2235/5248: Carbon, e.g. graphite - C04B 2235/5436: micrometer sized, i.e. from 1 to 100 micron - C04B 2235/6021: Extrusion moulding - C04B 2235/6562: Heating rate - C04B 2235/6565: Cooling rate - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - C22C: ALLOYS (treatment of alloys C21D, C22F) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS ## Abstract A method is disclosed for forming extrudate filament, which consist essentially of fiber, organic binder, and metal and/or ceramic. The extrudate filament can be spooled, or used to form preforms, and/or assemblages of preforms. In further methods, the extrudate filament and/or preforms can be used to fabricate fiber-reinforced metal-matrix or ceramic-matrix or metal and ceramic matrix composite parts, which consist essentially of fiber in a matrix of metal, or ceramic, or metal and ceramic, respectively. ## Claims ### Claim 1 A method comprising: forming an extrudate filament by: (a) tensioning and spreading apart a plurality of fibers; (b) melting a thermoplastic binder; (c) applying at least one of metal powder and ceramic powder (“powder”), and the melted thermoplastic binder, to the plurality of fibers; and (d) cooling, to a temperature below a temperature at which the thermoplastic binder melts, the fibers having the applied powder and thermoplastic binder. ### Claim 2 (depends on 1) The method of claim 1 wherein the powder is applied to the fibers before the thermoplastic binder. ### Claim 3 (depends on 1) The method of claim 1 wherein the powder is applied to the fibers at the same time as the thermoplastic binder. ### Claim 4 (depends on 1) The method of claim 1 wherein the powder and thermoplastic binder are melt-blended together. ### Claim 5 (depends on 4) The method of claim 4 wherein the melt-blended powder and thermoplastic binder are sprayed onto the fibers. ### Claim 6 (depends on 4) The method of claim 4 wherein the fibers are dip coated in the melt-blended powder and thermoplastic. ### Claim 7 (depends on 1) The method of claim 1 wherein the powder and thermoplastic binder are compounded together and pelletized to form pellets. ### Claim 8 (depends on 7) The method of claim 7 wherein the pellets are melted in an extruder forming a flowable material, and wherein the flowable material is applied to the fibers. ### Claim 9 (depends on 8) The method of claim 8 wherein the fiber and flowable material are passed through a die, thereby forming an extrudate filament having a cross section defined by the shape of the die. ### Claim 10 (depends on 1) The method of claim 1 wherein the extrudate filament is cooled to room temperature and spooled. ### Claim 11 (depends on 1) The method of claim 1 wherein the extrudate filament is cooled to a temperature that is above the glass transition temperature, the method further comprising bending or otherwise shaping the extrudate filament, and then sizing the bent or shaped extrudate filament, thereby creating a preform. ### Claim 12 (depends on 11) The method of claim 11 further comprising: forming a layup in a mold, wherein the layup includes one or more preforms; and heating the layup to a temperature that is sufficient to melt the binder but insufficient to debind the binder, thereby forming a green body. ### Claim 13 (depends on 12) The method of claim 12 further comprising heating the green body to a temperature that is sufficient to debind the binder, thereby forming a brown body. ### Claim 14 (depends on 13) The method of claim 13 further comprising heating the brown body to a temperature that is sufficient to sinter the powder, thereby forming a part consisting essentially of the plurality of fibers in a matrix of: the metal, or the ceramic, or the metal and ceramic. ### Claim 15 (depends on 1) The method of claim 1 wherein the fibers are carbon fiber. ### Claim 16 (depends on 1) The method of claim 1 wherein the powder is stainless steel particles. ### Claim 17 (depends on 1) The method of claim 1 wherein the powder is zirconium oxide particles. ### Claim 18 (depends on 1) The method of claim 1 further comprising applying, to the plurality of fibers, at least one additive selected from the group consisting of rheological agents, surfactants, solvents, flow-control agents, surface-energy-lowering materials, and fillers. ### Claim 19 A method comprising: forming an extrudate filament, the extrudate filament consisting essentially of a plurality of fibers, organic binder, and at least one of metal particles and ceramic particles (“particles”); forming a layup in a mold, the mold defining the shape of a part, wherein the layup includes extrudate filaments that have been sized or shaped and sized; exposing the layup to heat and pressure, thereby forming a green body having the shape of the part; heating the green body to temperatures sufficient to debind the binder and sinter the particles, thereby forming a part consisting essentially of the fibers in a matrix of: the metal, or the ceramic, or the metal and ceramic. ### Claim 20 (depends on 19) The method of claim 19 wherein the fibers of the plurality are carbon fiber. ### Claim 21 (depends on 19) The method of claim 19 wherein the particles are stainless steel particles. ### Claim 22 (depends on 19) The method of claim 19 wherein the particles are zirconium oxide particles. ### Claim 23 (depends on 19) The method of claim 19 wherein the extrudate filament further includes at least one additive selected from the group consisting of rheological agents, surfactants, solvents, flow-control agents, surface-energy-lowering materials, and fillers. ### Claim 24 A composition comprising extrudate filament, the extrudate filament including: a plurality of continuous fibers; a thermoplastic resin disposed on the fibers; and one of metal particles, ceramic particles, or metal and ceramic particles disposed on the fibers.