Plastic and nonmetallic article shaping or treating: processes – Forming articles by uniting randomly associated particles – Stratified or layered articles
Reexamination Certificate
1999-06-29
2001-06-19
Silbaugh, Jan H. (Department: 1732)
Plastic and nonmetallic article shaping or treating: processes
Forming articles by uniting randomly associated particles
Stratified or layered articles
C264S109000, C264S250000, C264S264000, C264S257000, C264S510000, C264SDIG006
Reexamination Certificate
active
06248275
ABSTRACT:
The present invention relates in general to the manufacture of composite material components, such as syntactic foam cores.
BACKGROUND OF THE INVENTION
The formation of foam core types of composite material components from a slurry mixture by means of a molding process, is generally well known in the art. For the manufacture of foam core structures having complex curved shapes, performance of such molding processes is time consuming and expensive because of the required utilization of special molds. It is therefore an important object of the present invention to provide for a more economical and less time consuming type of molding process through which curve-shaped foam core types of composite material components may be synthesized from slurry mixtures.
SUMMARY OF THE INVENTION
In accordance with the present invention, a slurry mixture formulated from alcohol and microsphere particles having some binding agent therein, initially undergoes partial solidification on a flat molding surface lined with a release cloth. Such molding is performed during a period of 2 hours for example, to accommodate partial evaporation of the alcohol therefrom and to produce a partially solidified material having desired flexibility and non-cracking properties. Such initially molded, flexible material is transferred with its underlying release cloth from the flat surfaced mold to a curved-shaped molding surface, after inverting of the material to expose the release cloth lining on top thereof. The partially solidified material then undergoes additional drying after application to the curved molding surface until all of the alcohol is evaporated. Resin infusion is then performed while the material is held on the curved surface by a cover, resulting in a foam type of composite core product suitable for further fabrication as a curve shaped structural component.
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Castelli Vincent J.
Houghton Deborah A.
Zadra Dennis D.
Forrest John
Shuster Jacob
Silbaugh Jan H.
Staicovici Stefan
The United States of America as represented by the Secretary of
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