Process for preparing advanced composite structures
First Claim
1. A method of making a composite structure comprising:
- providing a preform for disposition within a mold cavity, said preform having a hollow core portion and further having an external configuration which is undersized relative to the cavity of the mold;
introducing said preform into said cavity having an internal configuration appropriate to the configuration of a finished part;
plugging one or more openings to the core of said preform with one or more plugs to prevent polymer flow from these openings;
introducing polymer into the core of the preform;
heating the preform together with the polymer in the core so as to melt the polymer in the preform in the core;
applying pressure to the polymer in the core of the preform via one or more remaining unplugged openings to the core of the preform to cause expansion of the preform against the internal configuration of the mold cavity and to consolidate the preform to form a finished part;
cooling the finished part while maintaining pressure on the core; and
removing the finished part from the mold.
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Accused Products
Abstract
A novel procedure for molding composite structures is disclosed wherein the finished part exhibits a net shape geometry requiring minimal further machining and displaying enhanced consolidation and surface characteristics. A composite preform having a hollow core portion containing a polymer insert is introduced into a mold cavity. One end of the preform core is sealed and the preform together with the polymer insert is heated to melt the composite matrix and core polymer. Pressure is applied to the core at the other end of the part, causing radial expansion of the part against the molded cavity and consolidation of the composite into a finished part. A product finished part is also disclosed and is useful as a component of an orthopedic implant.
32 Citations
16 Claims
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1. A method of making a composite structure comprising:
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providing a preform for disposition within a mold cavity, said preform having a hollow core portion and further having an external configuration which is undersized relative to the cavity of the mold; introducing said preform into said cavity having an internal configuration appropriate to the configuration of a finished part; plugging one or more openings to the core of said preform with one or more plugs to prevent polymer flow from these openings; introducing polymer into the core of the preform; heating the preform together with the polymer in the core so as to melt the polymer in the preform in the core; applying pressure to the polymer in the core of the preform via one or more remaining unplugged openings to the core of the preform to cause expansion of the preform against the internal configuration of the mold cavity and to consolidate the preform to form a finished part; cooling the finished part while maintaining pressure on the core; and removing the finished part from the mold. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method of making a composite structure comprising:
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providing a thermoplastic matrix, fiber reinforced preform for disposition within a mold cavity, said preform having a hollow core portion and further having an external configuration which is undersized relative to the cavity of the mold; introducing said preform into said cavity having an internal configuration appropriate to the configuration of a finished part; plugging one or more openings to the core of said preform with one or more plugs to prevent polymer flow from these openings; introducing polymer into the preform; heating the preform together with the polymer in the core so as to melt the polymer the preform in the core; applying pressure to the polymer in the core of the preform via one or more remaining, unplugged openings to the core of the preform to cause expansion of the preform against the internal configuration of the mold cavity and to consolidate the preform to form a finished part; cooling the finished part while maintaining pressure on the core; and removing the finished part from the mold. - View Dependent Claims (11, 12, 13, 14, 15, 16)
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Specification