Patent ID: 6238617
Filing Date: 2001-05-29
Classification: C04B,F01D,F02B,F05D,Y02T,Y10T

Abstract:
A method for forming a heat-resistant, thermally insulative, ductile turbocharger housing having a shaped interior surface, comprising the steps of:(a) forming a fiber preform in a shape of the turbocharger housing from continuous woven fibers;(b) inserting a mandrel having the shape of the interior surface of the turbocharger housing into the preform;(c) placing the preform in a cavity of a mold having a shape of the turbocharger housing;(d) forcing a liquid pre-ceramic polymer resin through the cavity to fill the cavity and saturate the preform;(e) heating the mold for a time and at a temperature sufficient to transform the preform saturated with the liquid pre-ceramic polymer resin to a polymer composite turbocharger housing;(f) removing the polymer composite turbocharger housing from the mold;(g) removing the mandrel; and(h) firing the polymer composite turbocharger housing in an inert atmosphere for a time and at a temperature sufficient to transform the pre-ceramic polymer resin to a ceramic.