Process for making an expanded fiber composite structure

Details Process for making an expanded fiber composite structure Process for making an expanded fiber composite structure

1991-06-13

1992-09-08

Woo, Jay H.

Plastic and nonmetallic article shaping or treating: processes

Carbonizing to form article

Agglomeration or accretion

264257, 264230, B29C 4318

Patent

active

051456150

ABSTRACT:
A process for forming an expanded fiber composite structure. The process includes impregnating a fiber mat with a plastic material, compressing the mat to impregnate the mat with the plastic, fully wetting each fiber and creating a substantially void-free fiber/plastic matrix, and reducing the compressive forces on the mat, allowing the fibers to rebound and expand the mat to a predetermined desired thickness, in the process creating interstitial voids. The structure is then cooled such that the plastic material stiffens and itself retains the structure at the desired thickness. The process optionally employs the addition of a molten polymeric material to the expanded or lofted mat, the material filling the interstitial voids in the structure. A composite structure may optionally be produced from a fully compressed plastic-impregnated fiber mat by heating to a temperature sufficient to loft the material and controlling the amount of lofting after the heat is applied.

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patent: 4690860 (1987-09-01), Radvan
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patent: 4751134 (1988-06-01), Chenoweth et al.
patent: 4752527 (1988-06-01), Sanzero et al.
patent: 4765915 (1988-08-01), Diehl
patent: 4775580 (1988-10-01), Dighton

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