Method and apparatus for manufacturing an article of a composite material
AssigneeObtec A/S
InventorsTorben Lindgaard, David Morgan Thomas
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AssigneeObtec A/S
InventorsTorben Lindgaard, David Morgan Thomas
Estimating the term…
A fiber-reinforced composite material and articles of manufacture formed thereof are formed by the method comprising: forming a compound material comprising a mixture of curable matrix-forming binder, heat resistant reinforcing fibers, and at least one particulate material, wherein the curable matrix-forming binder is 5 to 50% by volume of the compound material; curing the curable binder under simultaneous application of externally applied pressure and ultrasonic energy. Articles according to the invention are useful in a multitude of applications, particularly in applications where the article must retain its shape and properties when subjected to temperatures above the melting point of usual thermoplastic materials, e.g. above 1000.degree. C. The method provides dense, thermally stable, coherent composite materials having a desired high density. Forming and curing times are typically 10 times shorter than conventional methods, e.g. for brake pads in about 3-5 seconds.
A method for preparing a composite material with fiber reinforcement which comprises forming a compound material comprising a mixture of a curable matrix forming binder, heat resistant reinforcing fibers, and at least one particulate material, wherein the amount of said curable matrix-forming binder is in the range of from 5 to 50% by volume of the compound material, curing said binder in said mixture by compacting and heating said mixture by simultaneously subjecting said mixture to an externally applied pressure and ultrasonic energy applied by sonic oscillations at a given frequency, wherein said external pressure is in the range of from 60 to 200 bars and greater than an internal pressure of said mixture of compound material undergoing compaction and heating, wherein the amplitude of said sonic oscillations applied to said mixture is reduced sufficient to overcome the internal frictional forces between said reinforcing fibers and said at least one particulate material of said mixture undergoing compaction and heating without completely attenuating the sonic oscillations, and wherein an amount of said ultrasonic energy is dissipated into heat sufficient to ensure formation of a coherent, cured matrix binder in said compound material, and then recovering the resulting composite material.
Dependencies are inferred from the claim text.