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Process for manufacturing a composite material

  • US 5,076,986 A
  • Filed: 10/03/1990
  • Issued: 12/31/1991
  • Est. Priority Date: 10/03/1990
  • Status: Expired due to Fees
First Claim
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1. A process for manufacturing a composite material from a starting mixture comprising:

  • a binder made up of two components capable of reacting with each other, at least one of these two components being in a liquid form;

    at least one filler; and

    reinforcing fibers;

    said binder being selected from the group consisting of;

    hydraulic cement and water;

    potassium and sodium silicate and water;

    colloidal silica and water; and

    organic resins and hardeners or catalysts;

    said filler and fibers being selected to be chemically compatible with said binder and to give said composite material some predetermined structure and properties;

    wherein said process comprises the steps of;

    selecting an absorbing substance that is capable of absorbing the liquid component of said binder and is compatible with the solid component of said binder, said filler and said fibers, said absorbing substance constituting said filler or being a part thereof;

    determining the minimum amount of said absorbing substance that is sufficient to absorb all of said liquid component while keeping a dry aspect;

    impregnating all of said liquid component into said determined amount of said absorbing substance;

    mixing said absorbing substance impregnated with said liquid component of said binder with said solid component of said binder, if any, with said filler and with said fibers in a mixer for a period of time sufficient to obtain the requested mixture in a semidry and homogenous form, in which the fibers are fully dispersed;

    introducing said semidry mixture into a mold of a press and compressing said mixture under pressure for a period of time depending on the composition of the starting mixture and the predetermined properties of said composite material to be obtained; and

    subjecting said compressed material to ageing and hardening as a function of the kind of binder being used, in order to obtain the desired composite material.

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