Patent ID: 8043543
Filing Date: 2011-10-25
Classification: B29C,B29K,B29L

Abstract:
1. A method of making a plurality of dimensionally accurate carbon fiber reinforced, thermosetting polymer matrix articles, the method comprising: compressing a composite body comprising a three-dimensional carbon fiber reinforcing form that is infiltrated with a liquid thermosetting polymer precursor against a surface of a mold, the mold comprising a unitary body of iron-nickel alloy, the mold body having been fabricated from a slab of iron-nickel alloy and with a machined oversized cavity surface for receiving, shaping and thermal curing of the fiber reinforcing form and uncured polymer composite material, the cavity surface of the mold body having a coating layer of electroless nickel composition comprising up to 10 percent phosphorus by weight applied to the machined oversize cavity surface in a thickness of between about 60 micrometers and 90 micrometers for a predetermined size of the cavity surface and for contact by the composite material; and heating the composite body while it is compressed against the cavity surface to cure the polymer precursor into a solid polymeric matrix for the carbon fiber article, the mold body and coating experiencing repeated heating and cooling cycles during the making of the plurality of dimensionally accurate articles without delamination.