Compositions and methods for preparing multiple-component composite materials

Abstract

Methods for preparing fibrous monolith composite materials include continuously extruding cell and boundary material compositions. A filament is formed from a cell material composition and passed through a chamber of an extrusion assembly. A boundary material composition is extruded generally about the cell material composition filament and the two material compositions are co-extruded to form an extruded coated filament.

1 . A coextrusion assembly for a continuous coextrusion process for manufacture of a green coated fibrous monolith composite filament from at least two different material-laden compositions of a combination of thermoplastic polymer and a ceramic or metallic particulate, the assembly comprising: 
 an extrusion head including an extrusion outlet for extruding a first material-laden composition, and    a tapered nozzle including a nozzle outlet for guiding a second material-laden composition through the first material-laden composition,    the nozzle outlet positioned generally upstream of the extrusion outlet so that the second material-laden composition discharged from the nozzle is coated by the first material-laden composition before passing through the extrusion outlet.