Method of making a curved composite article

• US 4,891,084 A
• Filed: 12/14/1988
• Issued: 01/02/1990
• Est. Priority Date: 03/11/1986
• Status: Expired due to Fees

• Current Assignee: Raychem Limited (TE Connectivity Limited)
• Original Assignee: Raychem Limited (TE Connectivity Limited)
• Inventors: Senior, John M.
• Primary Examiner(s): Weston, Caleb
• Application Number:
  US07/287,586
• Time in Patent Office: 384 Days
• Field of Search: 156/196, 156/222, 156/223, 156/224, 156/242, 156/245, 156/288, 428/198, 428/224, 428/264, 428/284, 428/286, 428/287, 428/296, 428/411.1, 264/257, 264/258
• US Class Current: 156/196
• CPC Class Codes: B29C 43/006 Pressing and sintering powders, granules or fibres
• CPC Class Codes: B29C 70/086 and with one or more layers of pure plastics material, e.g. foam layers applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86
• CPC Class Codes: B29K 2071/00 Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2081/00 Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material
• CPC Class Codes: B29K 2271/00 Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as reinforcement
• CPC Class Codes: B29K 2281/00 Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as reinforcement
• CPC Class Codes: B29K 2313/00 Use of textile products or fabrics as reinforcement B29K2105/06 takes precedence
• CPC Class Codes: B29L 2031/3456 Antennas, e.g. radomes
• CPC Class Codes: B32B 2262/02 Synthetic macromolecular fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2305/08 Reinforcements
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/281 comprising polyimides
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/28 impregnated with or embedded in a plastic substance not used
• CPC Class Codes: H01Q 1/42 Housings not intimately mechanically associated with radiating elements, e.g. radome
• CPC Class Codes: Y10T 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]

Abstract

Curved composite articles, for example aeronautical radomes, are given a curved surface layer by consolidation under heat and pressure of a fusible polymeric fabric. Polyaryletherketone fabrics are preferred.

Claims

1. A method of making a composite article comprising (a) a curved body reinforced with a fiber reinforcement and (b) a substantially fiber-free curved surface layer formed by fusion and consolidation under heat and pressure of a fabric substantially composed of poly(aryl ether ketone) fibers of diameter less than 150 micrometers, the poly(aryl ether ketone) fibers having a softening temperature at least 50°

C. lower than the softening temperature of the fiber reinforcement;

comprising placing the said fabric in contact with the said body or an assembly which can be consolidated to form the said body, and applying heat and pressure to fuse and consolidate the fabric and produce the said surface layer.

2. A method according to claim 1, wherein the fabric was a woven fabric.

3. A method according to claim 1, wherein the poly(aryletherketone) has a repeat unit ##STR1## wherein Ph represents a p-phenylene moiety.

4. A method according to claim 1, wherein the body and fabric are shaped to the required curvature during the consolidation.

5. A method according to claim 1, wherein the body is provided by an assembly of polymeric material and reinforcing fibres which assembly is consolidated to form the body during the consolidation of the said fabric.

6. A method according to claim 1, wherein the body comprises a composite of polymeric material and reinforcing fibres.

7. A method according to claim 6, wherein the body comprise glass reinforcing fibres.

8. A method according to claim 6, wherein the body polymeric material amorphous aromatic polymer.

9. A method according to claim 6, wherein the body polymeric material comprises poly(amide/imide).