United Technologies Corporation

Antonio B Carulo

Karl M Prewo

David J McFarlin

Eric Minford

A method for manufacturing a discontinuous fiber reinforced glass matrix composites by injection molding using an injection nozzle that separates substantially all of a multifilament yarn into individual fibers resulting in a composite having greater crack resistance. The method comprises impregnating continuous filament yarn with glass matrix powders comprising glass, glass-ceramic powders or a mixture thereof. The impregnated multifilament yarn is chopped into discontinuous lengths and exposed to a temperature sufficient so that the matrix material softens. Pressure is applied to the heated impregnated multifilament yarn sufficient to displace the yarn into a mold through an injection nozzle contoured such that sufficient die-wall shear forces are generated to separate substantially all of the multifilament yarn into individual filaments. A mold pressure is maintained sufficient to prevent relaxation of the composite until the strain point of the glass is reached.

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Vernon, CT, United States of America

Antonio B Carulo