Manufacturing composite parts with integral porous components
AssigneeDavid G. Haverty
InventorDavid G. Haverty
Life of this patent
Estimating the term…
Abstract
A molding process in which a material with an open cell, porous structure 10 is placed, aligned or supported inside a suitable enclosed holding device. Another molding material 20 is subsequently injected into the said holding device while gas and/or pressure is sequentially applied to the said holding device, causing a synergistic interaction and joining between the said materials to take place. During the processing phase, gas is evenly dispersed throughout the porous core, effectively equalizing cavity pressure and permitting an even flow pattern to exist, encapsulating or sandwiching the said porous structure, thus forming a composite material with physical properties which are substantially greater than the individual components.
Claims10
A method of forming a coated porous article comprising the steps of:
- a) positioning a porous material which is permeable to gas within a holding device, and
- b) applying gas into the said holding device so as to saturate the porous component with gas, wherein,
- c) the application of a liquid material into the said holding device is displaced such that the said porous material is coated, and
- d) allowing sufficient time for the pressure within the said holding device to equalize, and
- e) allowing sufficient time for the liquid coating to be shaped by the said holding device.
A method for substantially increasing the physical characteristics of an article by molding a uniform layer of material around a porous article forming a composite material with properties greater than those of the said components comprising the steps of:
- a) applying a porous material which is permeable to gas within an enclosed holding device, and
- b) applying gas into the said holding device so as to saturate the porous component with gas, and
- c) applying a curable liquid material into the holding device so as to coat the said porous material, and
- d) allowing the said liquid material to be shaped by the said holding device, while
- e) allowing sufficient time for pressure within the said holding device to equalize and the said liquid material to cure.
Dependencies are inferred from the claim text.