Thermoplastic cylinder and process for manufacturing same
AssigneeTRE Corporation
InventorBrian T. Lundy
Life of this patent
Estimating the term…
Abstract
A fiber/thermoplastic resin matrix cylinder with a metal lining and a process for manufacturing such a cylinder using metal plasma spray and filament winding techniques are disclosed. In the manufacturing process, a molten metal plasma spray is deposited on a heated and rotating mandrel. After the metal layer has cooled, filament winding techniques are used to deposit a layer of graphite fibers and thermoplastic resin around the metal layer, after which the mandrel is removed. The metal layer remains bonded to the fiber/thermoplastic layer. The process results in a fiber/thermoplastic resin matrix cylinder of low cost, light weight, durability, and survivability.
Claims21
A process for manufacturing a hollow thermoplastic structure with an inner metal layer comprising the steps of:
- (a) providing a mandrel;
- (b) providing a molten metal spray and directing it onto the surface of the mandrel to form a layer of metal covering the mandrel;
- (c) depositing high strength fibers and thermoplastic resin on top of the metal layer so as to form a structure having a matrix of fibers and resin surrounding the metal layer;
- and
- (d) separating the resulting structure from the mandrel.
A process for manufacturing a hollow thermoplastic structure with an inner metal layer comprising the steps of:
- (a) providing a mandrel;
- (b) rotating and applying heat to the mandrel;
- (c) directing a molten metal spray at the surface of the rotating and heated mandrel, the metal spray forming a layer of metal covering the mandrel;
- (d) allowing the metal layer to solidify;
- (e) maintaining the mandrel and metal layer at a temperature sufficient to melt a thermoplastic resin;
- (f) depositing high strength fibers impregnated with a thermoplastic resin on top of the heated metal layer, thereby melting the resin;
- (g) allowing the thermoplastic resin to solidify, thereby forming a matrix layer of fibers and resin surrounding the metal layer;
- and
- (h) removing the mandrel.
A process for manufacturing a hollow thermoplastic structure with an inner metal layer comprising the steps of:
- (a) providing a mandrel;
- (b) rotating and applying heat to the mandrel until the mandrel surface temperature is approximately 400.degree. Fahrenheit;
- (c) providing a wire of the composition desired for the inner metal layer;
- (d) heating the end of the wire to its melting temperature and providing additional wire as the end melts;
- (e) directing a high velocity and high pressure stream of air at the melting end of the wire toward the surface of the rotating and heated mandrel, thereby forming a metal spray, until a metal layer of the desired thickness is deposited on the mandrel;
- (g) removing the source of heat applied to the mandrel and allowing the metal layer to cool down to a temperature suitable for application of cleaning solvents;
- (h) applying cleaning solvents to the metal layer;
- (i) applying heat to the mandrel and metal layer to maintain the temperature of the metal layer at a temperature sufficient to melt a thermoplastic resin;
- (j) depositing continuous high strength fibers impregnated with a thermoplastic resin on top of the heated metal layer in a helical and circumferential pattern, thereby melting the resin;
- (k) removing the source of heat applied to the mandrel and metal layer and allowing the mandrel and metal layer to cool down to a temperature sufficient to solidify the thermoplastic resin, thereby forming a matrix layer of fibers and resin surrounding the metal layer;
- and
- (l) removing the mandrel and surface finishing the resulting hollow thermoplastic structure with inner metal layer.
A cylinder having an outer layer of a fiber thermoplastic resin matrix and an innermost layer of metal directly contacting the outer layer, the innermost layer of metal being of a thickness that is capable of avoiding bending or splintering upon piercing of the cylinder by small arms fire.
A hollow cylinder comprising a thin metal spray cylinder interior layer formed by metal spraying, the metal layer forming the innermost surface of the cylinder, and a fiber and thermoplastic resin matrix surrounding and directly contacting the metal layer.
An actuator cylinder for use with a piston reciprocating within the cylinder, the cylinder having a thin metal innermost layer against which the piston reciprocates and an outer layer comprised of a matrix of fibers and thermoplastic resin, the innermost layer and outer layer being in direct contact and securely bonded together and the innermost layer being of a thickness that is capable of avoiding bending or splintering upon piercing of the actuator cylinder by small arms fire.
Dependencies are inferred from the claim text.