Method and apparatus for producing composites

Abstract

A method and system (10) for producing a composite material (108) from particles (102) and binder (104), is described. The system includes a feed zone (12), a unilayering zone (14), a mat reforming zone (16) and a compaction zone (18) all closely coupled to reduce time and allow the use of fast setting binders. A preformed feed mat (100) is fed into the spike wheels (22 and 24) of the feed zone. The spike wheels extract particles from the premat and impinge the particles onto an oscillating shield (26) in the layering zone. The oscillating shield moves across the thickness of the mat-forming zone depositing the particles uniformly on the trailing edge of the reformed mat (106) at the top (48A) of the tunnel conveyor (48) of the mat reforming zone. As the particles move past the lower end (26B) of the shield a binder is added to the particles. Overlays or release films (50) are introduced at the top of both sides of the tunnel conveyor so as to engage the surfaces of the reformed mat. When the reformed mat of particles and binder exits from the bottom (48B) of the tunnel conveyor, the mat immediately enters the converging conveyors (54 and 56) of the compaction zone. The converging conveyors compact the mat to the final thickness of the composite material.

Dependencies are inferred from the claim text.