Compositions and methods for preparing multiple-component composite materials

• US 20060008549A1
• Filed: 09/10/2004
• Published: 01/12/2006
• Est. Priority Date: 12/04/2000
• Status: Abandoned Application

• Current Assignee: BAE Systems Unmanned Aircraft Programs, Inc. (Rtx Corporation)
• Original Assignee: Advanced Ceramics Research, Inc. (Rtx Corporation)
• Inventors: Rigali, Mark J., Sutaria, Manish P., Gafner, Felix H., Cook, Randy C., Cipriani, Ronald A., Egner, Randy
• Application Number:
  US10/938,076
• Publication Number:
  US 20060008549A1
• Time in Patent Office: Days
• US Class Current: 425/133.100
• CPC Class Codes: B22F 3/20 by extruding
• CPC Class Codes: B28B 1/008 made from two or more materials having different characteristics or properties casting for producing layered articles B28B1/16; feeding several succesive layers, optionally of different materials B28B13/022; coating B28B11/04; applying material to surfaces to form a permanent layer thereon B28B19/00
• CPC Class Codes: B28B 1/42 using mixtures containing fibres, e.g. for making sheets by slitting the wound layer
• CPC Class Codes: B28B 3/2645 using means for inserting reinforcing members
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/06 Rod-shaped
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/15 incorporating preformed parts or layers, e.g. extrusion moulding around inserts
• CPC Class Codes: B29C 48/34 Cross-head annular extrusion nozzles, i.e. for simultaneously receiving moulding material and the preform to be coated
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: C04B 2235/6021 Extrusion moulding
• CPC Class Codes: C04B 35/62227 obtaining fibres
• CPC Class Codes: C04B 35/62231 based on oxide ceramics
• CPC Class Codes: C04B 35/62272 based on non-oxide ceramics carbon nanotubes C01B32/15; carbon fibers D01F9/12
• CPC Class Codes: C04B 35/62277 Fibres based on carbides
• CPC Class Codes: C04B 35/62286 Fibres based on nitrides
• CPC Class Codes: C04B 35/62844 Coating fibres
• CPC Class Codes: C04B 35/62886 by wet chemical techniques
• CPC Class Codes: C04B 35/62892 with a coating layer consisting of particles
• CPC Class Codes: C04B 35/634 Polymers C04B35/636 takes precedence
• CPC Class Codes: C22C 47/06 : by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element
• CPC Class Codes: C22C 49/14 : characterised by the fibres or filaments
• CPC Class Codes: D01F 9/08 : of inorganic material working or processing of metal wire B21F; from softened glass, minerals or slags C03B37/00

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.

Claims

1. A coextrusion assembly for a continuous coextrusion process for manufacture of a green coated fibrous monolith composite filament from at least two different material-laden compositions of a combination of thermoplastic polymer and a ceramic or metallic particulate, the assembly comprising:

an extrusion head including an extrusion outlet for extruding a first material-laden composition, and

a tapered nozzle including a nozzle outlet for guiding a second material-laden composition through the first material-laden composition,

the nozzle outlet positioned generally upstream of the extrusion outlet so that the second material-laden composition discharged from the nozzle is coated by the first material-laden composition before passing through the extrusion outlet.