US4852630A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Short fiber preform, method of making it, and composite material manufactured from it
Assignee: Toyota Motor Corp
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Filing: 1987-02-17
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Granted: 1989-08-01
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Expires: 2007-02-17
Abstract
Abstract A preform for being embedded in a matrix material for making a composite material is made essentially of many short fibers stuck together by a quantity of dried binder. This preform has a first portion in which the fiber volume proportion is relatively high, a second portion in which the fiber volume proportion is relatively low, and a third portion, joining between the first portion and the second portion, in which the fiber volume proportion changes substantially continuously from its portion adjoining to the first portion to its portion adjoining to the second portion. Thereby, the characteristics of the composite material, such as its strength, heat and wear resistance, and machinability and workability and characteristics with respect to wear on a mating member, alter smoothly from the first portion to the second portion without any severe discontinuity, thus ensuring that no points of weakness are caused. A method for making such a preform, and a composit material object manufactured using such a preform, which may be an engine piston, are also disclosed.
Inventors
- 👤 Kaneo Hamajima
- 👤 Atsuo Tanaka
- 👤 Masahiro Kubo
- 👤 Tadashi Dohnomoto
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 19:32
CPC Classifications
C; C04; C04B; C04B28/00; C04B28/005; B; B29; B29B; B29B11/00; B29B11/14; B29B11/16; B29B15/00; B29B15/08; B29C; B29C70/00; B29C70/04; B29C70/06; B29C70/10; B29C70/12; B29C70/14; B31; B31F; B31F7/00; B31F7/006; C22; C22C; C22C47/00; C22C47/02; C22C47/06; C22C47/08; F; F02; F02F; F02F7/00; F02F7/0085; B29C2793/00; B29C2793/0054; B29C43/00; B29K; B29K2995/00; B29K2995/0037; B29K2995/0063; B29K2995/0064; B29L; B29L2031/00; B29L2031/748; B29L2031/7494; C04B2111/00; C04B2111/00241; C04B2111/00405; C04B2111/00474; C04B2111/00905; C04B2111/00913; C04B2111/00931; F05; F05C; F05C2251/00; F05C2251/04; F05C2251/042; F05C2253/00; F05C2253/16; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12458; Y10T428/12486
Claims Analysis
Total Claims: 14
Claim 1
Independent Claim
252 words
A method for making a composite material wherein a matrix material selected from the group consisting of magnesium alloy and aluminum alloy is reinforced by fibers embedded therein, and wherein said method comprises: a) preparing a mass of a mixture of fibers selected from the group consisting of alumina, carbon, potassium titanate, alumina-silica and silicon carbide fibers and an inorganic binder of silica or alumina, said binder being in such a partially dried condition that said mass is uniformly deformable under compression; b) compressing a portion of said mass with said binder being in said partially dried condition so as to increase the density of said fibers in said portion from that in the remainder of said mass, and wherein for said compression, a first portion of the moist mass is substantially compressed, a second portion of the moist mass is compressed to a relatively low extent, and a third portion, joining between said first portion and said second portion, is compressed by an amount which changes substantially continuously from the portion adjoining to said first portion to the portion adjoining to said second portion; c) drying said mass to harden said binder; d) infiltrating under pressure a molten alloy selected for said matrix into interstices of said mass to fill said interstices while substantially maintaining a fiber work structure of said mass under the binding force of said binder; and e) solidifying said molten alloy with said fiber work structure of said mass being embedded in the matrix of said alloy.
Claim 2
Independent Claim
252 words
A method for making a composite material wherein a matrix material selected from the group consisting of magnesium alloy and aluminum alloy is reinforced by fibers embedded therein, and wherein said method comprises: a) preparing a mass of a mixture of fibers selected from the group consisting of alumina, carbon, potassium titanate, alumina-silica and silicon carbide fibers and an inorganic binder of silica or alumina, said binder being in such a partially dried condition that said mass is uniformly deformable under compression; b) compressing a portion of said mass with said binder being in said partially dried condition so as to increase the density of said fibers in said portion from that in the remainder of said mass, and wherein for said compression, a first portion of the moist mass is substantially compressed, a second portion of the moist mass is compressed to a relatively low extent, and a third portion, joining between said first portion and said second portion, is compressed by an amount which changes substantially continuously from the portion adjoining to said first portion to the portion adjoining to said second portion; c) drying said mass to harden said binder; d) infiltrating under pressure a molten alloy selected for said matrix into interstices of said mass to fill said interstices while substantially maintaining a fiber work structure of said mass under the binding force of said binder; and e) solidifying said molten alloy with said fiber work structure of said mass being embedded in the matrix of said alloy.
Claim 3
Dependent Claim
20 words
A method according to claim 1, wherein in step (b) said remainder of said moist mass is not substantially compressed.
Claim 4
Dependent Claim
15 words
A method according to claim 1, wherein in step (b) said binder is partially hardened.
Claim 5
Dependent Claim
19 words
A method according to claim 1, wherein in step (c) said binder is hardened by heating said moist mass.
Claim 6
Dependent Claim
28 words
A method according to claim 1, wherein during at least a part of step (c) the compression of said moist mass performed in step (b) is kept applied.
Claim 7
Dependent Claim
25 words
A method according to claim 1, wherein, before the commencement of step (c), the compression of said moist mass performed in step (b) is released.
Claim 8
Dependent Claim
28 words
A method according to claim 1, further comprising the step, performed between step (a) and step (b), of incising a slot in the surface of said moist mass.
Claim 9
Dependent Claim
39 words
A method according to claim 7, wherein said slot extends generally along the boundary between said proper portion of said moist mass which is more compressed in step (b) and said remainder thereof which is not so much compressed.
Claim 10
Dependent Claim
24 words
A method according to claim 1, wherein said compression of said moist mass in step (b) is performed by means of a pressing member.
Claim 11
Dependent Claim
17 words
A method according to claim 9, wherein said pressing member is formed with a sloping edge portion.
Claim 12
Dependent Claim
95 words
A method according to claim 9, wherein during step (b) the main portion of said pressing member compresses and defines said proper portion of said moist mass, and said sloping edge portion of said pressing member compresses and defines a transitional portion of said moist mass joining between said proper portion of said moist mass and said remainder of said moist mass, the compression amount of said transitional portion changing substantially continuously from its portion adjoining to said proper portion of said moist mass to its portion adjoining to said remainder of said moist mass.
Claim 13
Dependent Claim
18 words
A method according to claim 11, wherein said sloping edge portion of said pressing member is substantially straight.
Claim 14
Dependent Claim
18 words
A method according to claim 11, wherein said sloping edge portion of said pressing member is substantially circular.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-07-31 | 1993-01-30 | 1993-08-01 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-07-31 | 1997-01-30 | 1997-08-01 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-07-31 | 2001-01-30 | 2001-08-01 | $7700.00 | Window Closed / Lapsed |