Compositions and methods for preparing multiple-component composite materials
AssigneeAdvanced Ceramics Research, Inc.
InventorsMark J. Rigali, Manish P. Sutaria, Felix H. Gafner, Ronald A. Cipriani, Randy Egner, Randy C. Cook
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Abstract
Methods for preparing fibrous monolith composite materials include continuously extruding cell and boundary material compositions. A filament is formed from a cell material composition and passed through a chamber of an extrusion assembly. A boundary material composition is extruded generally about the cell material composition filament and the two material compositions are co-extruded to form an extruded coated filament.
Claims18
A method for continuous fibrous monolith composite coextrusion comprising:
- a) producing a first material-laden composition comprising a thermoplastic polymer and at least about 40 volume % of a ceramic or metallic particulate;
- b) extruding the first material laden composition into a filament;
- c) producing a second material-laden composition comprising a thermoplastic polymer and at least about 40 volume % of a ceramic or metallic particulate that is different in composition than the first material laden composition;
- d) passing the filament through an coextrusion assembly, the coextrusion assembly comprising an extrusion head, a tapered nozzle, a spinnerette, a spinnerette housing, a guide rod support, and a guide rod;
- e) coating the filament with the second material-laden composition as the filament passes through the coextrusion assembly to form a coated filament;
- f) arranging the coated filament into a desired architecture to form a fibrous monolith composite.
A method for continuous formation of a fibrous monolith material comprising steps of:
- a) forming an elongate filament of a cell material;
- b) continuously feeding the filament of cell material through a first nozzle opening of a first nozzle member into a chamber;
- c) continuously extruding a boundary material into said chamber and about the cell material as the cell material is discharged from the first nozzle opening;
- d) continuously extruding the composite cell and boundary material from the chamber through a second nozzle opening to form an extrudate of fibrous monolith material.
Dependencies are inferred from the claim text.