Method of manufacturing articles utilizing a composite material having a high density of small particles in a matrix material

Abstract

A method of manufacturing articles utilizing a composite material having a high density of small particles such as microspheres in a matrix material is disclosed. In accordance with one aspect of the present invention, at least first and second layers of flanking material are disposed in a generally non-parallel relationship with respect to each other and then are pulled through a die. While the flanking material layers are being pulled through the die, a composite material is injected into a space defined between the at least first and second layers of flanking material. The composite material and the at least first and second layers of flanking material are heated as they pass through the die to cure the composite material and bond the at least two flanking material layers to the composite material, thereby forming a cured article.

What is claimed is:  
     
         1 . A method of manufacturing an article using a composite material that has a high density of small particles such as microspheres disposed in a matrix material, said method comprising the steps of: 
 providing a source of said composite material;    providing at least first and second layers of flanking material;    pulltruding said at least first and second layers of flanking material through a die, said first and second layers of flanking material being disposed in a generally non-parallel relationship with respect to each other;    injecting said composite material into a space defined between said at least first and second layers of flanking material; and    heating said injected composite material and said at least first and second layers of flanking material as they pass through said die to cure said composite material and to form a cured article.    
     
     
         2 . The method of  claim 1  wherein said flanking material is chosen from a group consisting of: carbon fibers, glass fibers, uni-directional fibers, cross-woven fibers, matte fibers, fiber braid, uni-directional stitch woven carbon fiber braid, carbon felt, felt, plastic, leather, foil, metal, composite, thermoplastic, thermoset, resin, fiberglass, and ceramic.  
     
     
         3 . The method of  claim 1  further comprising the step of providing a third layer of flanking material, wherein said pulling step comprises the step of pulling said first, second, and third layers of flanking material through said die, and wherein said injecting step comprises injecting said composite material into a space defined between adjacent surfaces of said first, second, and third flanking material layers.  
     
     
         4 . The method of  claim 3  wherein said first and third layers of flanking material are disposed in a generally parallel relationship with respect to each other.  
     
     
         5 . The method of  claim 3  wherein a wedge is used to inject said composite material into a space defined between said first, second, and third layers of flanking material, said wedge having a first and second inclined surfaces, said first and second layers of flanking material being guided into said die at least in part by contact with at least a portion of said first and second inclined surfaces.  
     
     
         6 . The method of  claim 1  wherein a wedge is used to inject said composite material into a space defined between said at least first and second layers of flanking material as they are being pulled through said die, said at least first and second layers of flanking material being guided into said die at least in part by contact with at least a portion of wedge.  
     
     
         7 . The method of  claim 6  wherein at least one comb is disposed on at least a portion of said wedge, an alignment of any fibers in said first layer of flanking material being generally increased by contact with said at least one comb.  
     
     
         8 . The method of  claim 1  wherein at least a portion of said cured article is generally planar.  
     
     
         9 . The method of  claim 8  wherein said cured article is generally planar.  
     
     
         10 . The method of  claim 1  further comprising the step of forming said cured article into a desired shape.  
     
     
         11 . The method of  claim 10  wherein said forming step comprises machining at least a portion of said cured article.  
     
     
         12 . The method of  claim 10  wherein said forming step comprises cutting said cured article to a desired length.  
     
     
         13 . An article, comprising: 
 at least first and second layers of flanking material that are disposed in a generally non-parallel relationship with respect to each other; and    a layer of composite material that has a high density of small particles such as microspheres disposed in a matrix material and that is bonded to a surface of said at least first and second layers of flanking material, said composite material being bonded to said at least one first and second layers of flanking material by pulltruding said at least first and second layers of flanking material through a die, injecting said composite material into a space defined between said at least first and second layers of flanking material as they pass through said die, heating said injected composite material and said at least first and second layers of flanking material as they pass through said die to form a cured article, and forming said cured article into a desired shape.    
     
     
         14 . The article of  claim 13  wherein said flanking material is chosen from a group consisting of: carbon fibers, glass fibers, unidirectional fibers, cross-woven fibers, matte fibers, fiber braid, unidirectional stitch woven carbon fiber braid, carbon felt, felt, plastic, leather, foil, metal, composite, thermoplastic, thermoset, resin, fiberglass, and ceramic.  
     
     
         15 . The article of  claim 13  wherein at least a portion of said cured article is generally planar.  
     
     
         16 . The article of  claim 15  wherein said cured article is generally planar.  
     
     
         17 . A method of manufacturing an article using a composite material that has a high density of small particles such as microspheres disposed in a matrix material, said method comprising the steps of: 
 providing a source of said composite material;    providing at least one layer of flanking material;    pulltruding said at least one layer of flanking material through a die;    injecting said composite material onto a surface of said at least one layer of flanking material;    heating said injected composite material and said at least one flanking material as it passes through said die to cure said composite material and form a cured article;    wherein a wedge is used to inject said composite material onto said surface of said at least one layer of flanking material as it is being pulled through said die, said first layer of flanking material being guided into said die at least in part by contact with at least a portion of said wedge; and wherein at least one comb is disposed on at least a portion of said wedge, an alignment of any fibers in said at least one layer of flanking material being generally increased by contact with said at least one comb.