Patent ID: 7045083

Claim:
A method for forming composite components, the method comprising: (a) providing a mold having a mold cavity, at least a portion of the mold cavity having a selected shape for forming a composite component; (b) providing sections of adjacent fibers, the fibers being parallel to each other and being coated with a fugitive binder that adheres the fibers to each other; (c) arranging the fibers within the mold cavity and assembling the mold; then (d) heating the fibers to a temperature sufficient to pyrolyze the binder leaving no charred material or residue in the mold other than the fibers; then (e) injecting resin into the mold cavity, the resin forming a matrix enclosing the fibers; then (f) curing the resin; and then (g) removing the composite component from the mold cavity; wherein: step (a) comprises providing a mold that has at least one injection port and at least one vent port, the ports communicating an exterior of the mold and the mold cavity; and step (d) further comprises flowing a heated gas into the mold cavity through the injection port and out of the mold cavity through the vent port, the heated gas pyrolyzing the fugitive binder.