US 9,283,734 B2Granted

Manufacturing apparatus and method of forming a preform

AssigneeGunite Corporation

InventorsNeil Anderson, Matt Kero

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Abstract

The present invention provides for a manufacturing apparatus for forming a ceramic preform from an extrudate having a first end and a second end. A cutter forms the first and second ends of the extrudate complementary to each other such that the first and second ends of the extrudate align with each other in a spaced relationship to define a preform having a substantially uniform exterior surface and a substantially uniform thickness. The present invention provides for a method of forming the preform from the extrudate having the first and second ends utilizing a mandrel. The method includes the step of aligning the second end complementary to the first end of the first layer in a spaced relationship to define the preform having the substantially uniform exterior surface and the substantially uniform thickness.

Claims27

Dependent claims

A method of forming a preform from an extrudate having a first end and a second end utilizing a mandrel rotatable about an axis and having an outer surface spaced radially from the axis, said method comprising the steps of:

forming the first end of the extrudate;
wrapping the extrudate about the mandrel while rotating the mandrel about the axis to form a first layer having the first end abutting the outer surface of the mandrel;
cooling the mandrel such that the first layer of the extrudate adheres to the outer surface of the mandrel and remains adhered to the outer surface as the mandrel rotates about the axis;
applying pressure to the first layer during wrapping of the extrudate about the mandrel;
forming the second end of the extrudate complementary in configuration to the first end;
wrapping the extrudate about the mandrel while rotating the mandrel about the axis to form a second layer on top of the first layer with the second end spaced from the outer surface of the mandrel;
applying pressure to the second layer during wrapping of the extrudate about the mandrel;
and
aligning the second end complementary to the first end of the first layer in a spaced relationship to define the preform having a substantially uniform exterior surface and a substantially uniform thickness.

6 more elements

A method of forming a ceramic preform comprising ceramic particles and ceramic fibers having an aspect ratio of greater than or equal to 10:1 and the ceramic fibers substantially randomly orientated in three dimensions utilizing an extruder and a mandrel rotatable about an axis and having an outer surface spaced radially from the axis, said method comprising the steps of:

extruding the ceramic particles and the ceramic fibers through the extruder to form an extrudate having a first end and a second end with the extrudate having a substantially rectangular cross-section between the first and second ends and having planar exterior surfaces;
forming the first end of the extrudate;
wrapping the extrudate about the mandrel while rotating the mandrel about the axis to form a first layer having the substantially rectangular cross-section and having the first end abutting the outer surface of the mandrel;
applying pressure to the first layer during wrapping of the extrudate about the mandrel;
forming the second end of the extrudate complementary in configuration to the first end;
wrapping the extrudate about the mandrel while rotating the mandrel about the axis to form a second layer having the substantially rectangular cross-section on top of the first layer with the second end spaced from the outer surface of the mandrel;
applying pressure to the second layer during wrapping of the extrudate about the mandrel;
and
aligning the second end complementary to the first end of the first layer in a spaced relationship to define the preform having a substantially uniform exterior surface and a substantially uniform thickness.

6 more elements

Dependencies are inferred from the claim text.

Facts

Application: 13/149,292Filed 31 May 2011 · us provisional application
Priority: 28 May 2010
Published: US 2012/0183707 A119 Jul 2012
Granted: 15 Mar 2016
Term ends: Not estimatedThe source records don’t support an estimate.

Classification51 codes

B32B 18/00
Layered products essentially comprising ceramics
B28B 1/42
By wrapping, e.g. winding: using mixtures containing fibres, e.g. for making sheets by slitting the wound layer
B28B 21/22
Using compacting means: using rotatable mould or core parts
B28B 21/42
Methods or machines specially adapted for the production of tubular articles: by shaping on or against mandrels or like moulding surfaces