Process of making boron-fiber reinforced composite tape

• US 6,500,370 B1
• Filed: 07/18/2000
• Issued: 12/31/2002
• Est. Priority Date: 07/18/2000
• Status: Expired due to Fees

• Current Assignee: Old Dominion University Research Foundation
• Original Assignee: United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration
• Inventors: Johnston, Norman J., Belvin, Harry L., Marchello, Joseph M., Cano, Roberto J.
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US09/620,274
• Time in Patent Office: 896 Days
• Field of Search: 264/85, 264/136, 264/137, 264/171.13, 156/180, 156/181, 156/298
• US Class Current: 264/85
• CPC Class Codes: B29B 15/122 with a matrix in liquid form, e.g. as melt, solution or latex
• CPC Class Codes: B29C 70/16 using fibres of substantial or continuous length non-woven fabrics per se D04H3/00
• CPC Class Codes: B29C 70/50 for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
• CPC Class Codes: Y10T 156/109 Embedding of laminae within face of additional laminae

Abstract

The invention is an apparatus and method for producing a hybrid boron reinforced polymer matrix composition from powder pre-impregnated fiber tow bundles and a linear array of boron fibers. The boron fibers are applied onto the powder pre-impregnated fiber tow bundles and then are processed within a processing component having an impregnation bar assembly. After passing through variable-dimension forming nip-rollers, the powder pre-impregnated fiber tow bundles with the boron fibers become a hybrid boron reinforced polymer matrix composite tape. A driving mechanism pulls the powder pre-impregnated fiber tow bundles with boron fibers through the processing line of the apparatus and a take-up spool collects the formed hybrid boron-fiber reinforced polymer matrix composite tape.

Claims

1. A method of producing a boron-fiber reinforced composite tape, comprising steps for:

(a) dispensing at least one array of boron fibers;

(b) applying a plurality of fiber tow bundles, said fiber tow bundles being pre-impregnated with a polymeric matrix, along at least one side of at the at least one dispensed array of boron fibers;

(c) heating the at least one dispensed array of boron fibers and the applied plurality of fiber tow bundles to a specific processing temperature which melts the polymeric matrix of the fiber tow bundles;

(d) wetting-out the heated at least one array of boron fibers and plurality of fiber tow bundles into an intial consolidated flat shape, wherein the heated at least one array of boron fibers are encapsulated within the plurality of fiber tow bundles so as to become a boron-reinforced composite tape;

(e) re-shaping the consolidated flat boron-reinforced composite tape into a pre-determined width; and

(f) spooling the consolidated, boron-reinforced composite tape.

2. The method of claim 1, wherein the plurality of fiber bundles comprises carbon fiber.

3. The method of claim 1, wherein the step for dispensing at least one array of boron fibers comprises using a pay-out creel for delivery of the at least one array of boron fibers.

4. The method of claim 1, wherein the step for dispensing at least one array of boron fibers comprises dispersing a plurality of linear arrays of boron fibers.

5. The method of claim 4, further comprising a step for mounting a plurality of linear arrays of boron fibers on a pay-out creel for delivery.

6. The method of claim 1, wherein the at least one array of boron fibers comprises boron fibers supported by polymeric thread.

7. The method of claim 1, wherein the at least one array of boron fibers comprises boron fibers supported by an adhesive.

8. The method of claim 1, wherein the step for heating employs an inert gas environment.

9. The method of claim 8, wherein the inert gas is nitrogen.

10. The method of claim 1, wherein the pre-determined width of the composite tape is approximately three inches.

11. A method of producing a boron-fiber reinforced composite tape, comprising steps for:

(a) supplying at least one array of boron fibers;

(b) supplying at least one array of fiber tow bundles, each fiber tow bundle being pre-impregnated with a polymeric matrix;

(c) heating the at least one array of fiber tow bundles so as to melt the polymeric matrix of the fiber tow bundles;

(d) wetting-out the melted polymeric matrix of the fiber tow bundles; and

(e) pressing the heated fiber tow bundles and the at least one array of boron fibers together to encapsulate the boron fibers within the melted polymeric matrix, whereby a consolidated boron fiber reinforced composite tape is formed.