Edward J Vaughn

US Patent:

46632255, May 5, 1987

Filed:

May 2, 1986

Appl. No.:

6/858974

Inventors:

Radcliffe W. Farley - Worcester PA
Edward A. Vaughn - Clemson SC
Clarke A. Rodman - East Providence RI
Edward C. Homonoff - Brooklyn CT

Assignee:

Allied Corporation - Morristown NJ

International Classification:

B32B 100
B29C 4514
D04H 158

US Classification:

428290

Abstract:

A fiber reinforced, composite article is manufactured by forming a nonwoven, air-laid batt from a single fiber type or a mixture of fibers. The batt is either resinated with a thermoplastic material or includes a thermoplastic binder fiber. The batt is formed into a preform having the desired shape in a through-air mold and heated sufficiently to set the thermoplastic material, so that the resulting preform retains the desired shape and is sufficiently stiff to withstand the pressure of the injected resin. The preform is then transferred to a resin injection mold, where the interstices between the fibers are saturated with an appropriate resin matrix. As the fibers of the preform are saturated (or after a saturation but before the resin sets) the resin transfer mold is compressed, thereby forming the preform into its final desired thickness and increasing the concentration of the fibers to give the preform appropriate strength. Accordingly, the preform retains the open characteristics permitting easy injection of the resin, while later being compressed to increase the concentration of the reinforcing fibers to give the resulting composite the appropriate strength.

US Patent:

48122831, Mar 14, 1989

Filed:

May 2, 1986

Appl. No.:

6/858785

Inventors:

Radcliffe W. Farley - Worcester PA
Edward A. Vaughn - Clemson SC
Clarke A. Rodman - East Providence RI
Edward C. Homonoff - Brooklyn CT

Assignee:

Allied-Signal Inc. - Morristown NJ

International Classification:

B29C 4302
D04H 154

US Classification:

264518

Abstract:

A molded article, for example, a filter or a preform used in the manufacture of fiber-reinforced composites, is manufactured from an air laid batt from a single fiber type or a mixture of fibers. The batt is either resinated with a thermoplastic material or includes a thermoplastic binder fiber. The batt is formed into the desired shape of the molded article in a through-air mold and heated sufficiently to set the thermoplastic material, so that the resulting article retains the desired shape. If the article is to be used as a fluid filter, it can be used either as it is removed from the mold if a filter of uniform density is desired, of the article can be further processed in a compression mold to densify portions of the article to thereby form, for example, a fluid impervious portion used as a gasket. If the article is to be used as a preform for a structural composite, it is then to be transferred to a resin injection mold.