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US 5,364,571 AGranted
Method of making a composite material
AssigneeAvco Corporation
InventorsThomas J. O'Connor, Mark J. Pistorino, John J. Gaffney, William T. Foulds
Life of this patent
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Abstract
Net shape composite articles are made by a molding process. The molded preform is densified in a process where the rate of temperature increase is controlled to prevent distortion. The densified composite objects are impregnated with a secondary material to provide desirable properties such as strength, stiffness, or oxidation resistance. Diverse parts such as golf clubs and engine parts can be made by the process.
Claims13
A method of making golf club head comprising the steps of:
- a. molding a mixture comprising carbon fibers and a carbon-containing resin into the shape of the golf club head;
- b. curing the molded carbon-containing resin;
- c. converting the molded carbon-containing resin to a porous carbonaceous matrix by gradually heating said molded resin up to its pyrolysis temperature over a broad temperature range including first predetermined temperature range increments at which gas is evolved therefrom more rapidly than at second predetermined temperature range increments within said broad range;
- d. controlling the heating rate during step (c) so that the temperature is gradually increased at a reduced rate of up to about 10.degree. F. per hour over said first predetermined temperature range increments, during periods of more rapid gas evolution, and at a higher rate of at least about 18.degree. F. per hour over said second predetermined temperature range increments, and
- e. impregnating the porous carbonaceous matrix with a secondary material imparting properties different than the carbonaceous matrix.
2 more elements
A method of making a composite molded article comprising the step of:
- a. molding a resinous material containing fibers into a predetermined shape;
- b. curing the resin;
- c. pyrolizing the resinous material to form a rigid porous matrix around the fibers by gradually heating said molded resin up to its pyrolysis temperature over a broad temperature range including first predetermined temperature range increments at which gas is evolved therefrom more rapidly than at second predetermined temperature range increments within said broad range;
- d. controlling the heating rate during step (c) so that the temperature is gradually increased at a reduced rate of up to about 10.degree. F. per hour over said first predetermined temperature range increments, during periods of more rapid gas evolution, and at a higher rate of at least about 18.degree. F. per hour over said second predetermined temperature range increments;
- e. impregnating the pores of the matrix with a second type of resin;
- and
- f. curing the second type of resin to strengthen the composite material.
4 more elements
Dependencies are inferred from the claim text.