US5335712A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Shaped bodies containing short inorganic fibers or whiskers and methods of forming such bodies
Assignee: Technical Ceramics Laboratories Inc
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Filing: 1992-04-06
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Granted: 1994-08-09
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Expires: 2012-04-06
Abstract
Abstract A fiber-organic composition includes from about 5% to 50% by volume of uniformly dispersed, non-planar or three dimensionally random oriented inorganic fibers or whiskers, and a thermoplastic material such as paraffin wax. The composition also includes surfactants to promote wetting and dispersion of the inorganic fibers or whiskers. These materials are subjected to high shear mixing to form a uniform randomly oriented three-dimensional dispersion of the inorganic fibers or whiskers. After molding the mixture in such a manner so as not to disrupt the uniform, three-dimensional orientation of the fibers or whiskers, a majority of the thermoplastic material is removed leaving a shaped body or preform having sufficient strength for handling. The shaped body or preform can then be infiltrated with molten metal or the like to form a metal matrix composite.
Inventors
- 👤 William J. Corbett
- 👤 Marvin C. Lunde
- 👤 Peter T. B. Shaffer
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 18:39
CPC Classifications
B; B22; B22F; B22F3/00; B22F3/22; B22F3/225; C; C04; C04B; C04B30/00; C04B30/02; C04B35/00; C04B35/01; C04B35/10; C04B35/111; C04B35/117; C04B35/14; C04B35/48; C04B35/486; C04B35/488; C04B35/515; C04B35/52; C04B35/56; C04B35/565; C04B35/573; C04B35/622; C04B35/626; C04B35/63; C04B35/6303; C04B35/6316; C04B35/71; C04B35/74; C04B35/76; C04B35/78; C04B35/80; C04B41/00; C04B41/009; C04B41/53; C04B41/60; C04B41/72; C08; C08K; C08K7/00; C08K7/02; C22; C22C; C22C47/00; C22C47/02; C22C47/025; C22C47/06; C22C47/08; C22C49/00; C22C49/02; C22C49/04; C22C49/06; B22F2998/00; C04B2111/00; C04B2111/00474; C04B2111/00905; C04B2111/00913; C04B2111/00922; C04B2235/00; C04B2235/02; C04B2235/50; C04B2235/52; C04B2235/5208; C04B2235/5216; C04B2235/522; C04B2235/5224; C04B2235/5228; C04B2235/5232; C04B2235/524; C04B2235/5244; C04B2235/5248; C04B2235/526; C04B2235/5264; C04B2235/5276; C04B2235/60; C04B2235/616; Y; Y10; Y10S; Y10S428/00; Y10S428/902; Y10T; Y10T428/00; Y10T428/12; Y10T428/12486; Y10T428/249921; Y10T428/249924; Y10T428/24994; Y10T428/29; Y10T428/2913; Y10T428/2918; Y10T428/30
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
195 words
A method for making a metal matrix composite comprising the steps of: (a) providing a mass of inorganic short fibers; (b) providing a mass of hot thermoplastic compound which is heated to a fluid state; (c) adding the short inorganic fibers into the heated thermoplastic compound to provide a mix having from about 10 to about 40% by volume of fiber; (d) adding additional organic ingredients to the fiber containing compound to form a moldable mixture; (e) subjecting the moldable mixture from step (d) to high shear mixing to thereby provide a high degree of three dimensional random orientation of fiber within the mixture; (f) providing a mold defining a predetermined shaped cavity; (g) introducing the moldable mixture from step (e) into the mold and cooling the mixture while maintaining the high degree of three dimensional random orientation; (h) removing the cooled molded or shaped mixture from the mold and extracting at least about 95% by volume of the organic material to thereby provide a shaped preform of fibers having sufficient strength to allow handling of the preform; and (i) introducing a molten metal into the preform while maintaining the structural integrity of the preform.
Claim 2
Independent Claim
195 words
A method for making a metal matrix composite comprising the steps of: (a) providing a mass of inorganic short fibers; (b) providing a mass of hot thermoplastic compound which is heated to a fluid state; (c) adding the short inorganic fibers into the heated thermoplastic compound to provide a mix having from about 10 to about 40% by volume of fiber; (d) adding additional organic ingredients to the fiber containing compound to form a moldable mixture; (e) subjecting the moldable mixture from step (d) to high shear mixing to thereby provide a high degree of three dimensional random orientation of fiber within the mixture; (f) providing a mold defining a predetermined shaped cavity; (g) introducing the moldable mixture from step (e) into the mold and cooling the mixture while maintaining the high degree of three dimensional random orientation; (h) removing the cooled molded or shaped mixture from the mold and extracting at least about 95% by volume of the organic material to thereby provide a shaped preform of fibers having sufficient strength to allow handling of the preform; and (i) introducing a molten metal into the preform while maintaining the structural integrity of the preform.
Claim 3
Dependent Claim
25 words
A method for making a metal matrix composite according to claim 1 in which the molten metal is introduced into the platform by capillary action.
Claim 4
Dependent Claim
26 words
A method for making a metal matrix composite according to claim 1 in which the molten metal is introduced into the platform by pressure assisted infiltration.
Claim 5
Dependent Claim
25 words
A method for making a metal matrix composite according to claim 1 in which the molten metal is introduced into the platform by vacuum infiltration.
Claim 6
Dependent Claim
25 words
A method for making a metal matrix composite according to claim 1 in which the molten metal is introduced into the preform by squeeze casting.
Claim 7
Dependent Claim
34 words
A method for making a metal matrix composite according to claim 1 which includes the step of supporting the shaped mixture during the extraction of the thermoplastic organic compound with a particulate inorganic material.
Claim 8
Dependent Claim
32 words
A method for making a metal matrix composite according to claim 1 wherein the mixture from step (d) is subjected to high shear for a period of at least about 30 minutes.
Claim 9
Dependent Claim
35 words
A method for making a metal matrix composite according to claim 1 wherein the hot mixture in step (g) is injected into a mold with a pressure of between about 10 to about 150 psi.
Claim 10
Dependent Claim
28 words
A method for making a metal matrix composite according to claim 1 which includes the step of forming ceramic bonds between the fibers at their points of contact.
Claim 11
Dependent Claim
34 words
A method for making a metal matrix composite according to claim 9 which includes the step of sintering the shaped body to thereby form a bond between the fibers at their points of contact.
Claim 12
Dependent Claim
28 words
A method for making a metal matrix composite according to claim 1 in which the fibers are bonded to one another at their points of contact by oxidation.
Claim 13
Dependent Claim
25 words
A method for making a metal matrix composite according to claim 1 which includes the step of adding ceramic particles to the thermoplastic organic compound.
Claim 14
Dependent Claim
26 words
A method for making a metal matrix composite according to claim 1 which includes the step of adding a metallic powder to the thermoplastic organic compound.
Claim 15
Dependent Claim
21 words
A method for making a metal matrix composite according to claim 13 which includes the step of sintering the metallic powder.
Claim 16
Dependent Claim
21 words
A method for making a metal matrix composite according to claim 13 which includes the step of densifying the shaped body.
Claim 17
Dependent Claim
27 words
A method for making a metal matrix composite according to claim 13 which includes the step of chemically converting the metal phase to form a ceramic compound.
Claim 18
Dependent Claim
31 words
A method for making a metal matrix composite according to claim 1 which includes the step of removing any entrapped air from the mixture before introducing the mixture into the mold.
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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) | 1997-08-08 | 1998-02-07 | 1998-08-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2001-08-08 | 2002-02-07 | 2002-08-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2005-08-08 | 2006-02-07 | 2006-08-09 | $7700.00 | Window Closed / Lapsed |