Injection molding of fiber reinforced articles
This is a division of copending application Ser. No. 07/410,195 filed on Sep. 21, 1989, now U.S. Pat. No. 5,061,423. 
    
    
     TECHNICAL FIELD 
     The present invention relates to injection molding, especially to injection port geometry and related processing parameters for producing fiber reinforced articles possessing a unique whorled, accordion like fiber plane orientation. 
     BACKGROUND ART 
     Fiber reinforcement is a known, commonly used method of increasing the mechanical properties of thermoplastic, glass, and glass ceramic materials. Hereafter referred to as molding compounds, these materials are described, for example, in U.S. Pat. Nos. 4,314,852, 4,324,843, and 3,926,904 (incorporated herein by reference). The fibers used for reinforcement vary according to the desired application. These fibers include: carbon base fibers, boron base fibers, glass fibers, silicon carbide fibers, metal fibers, and others. Carbon base fibers are light weight, strong, highly electrically conductive, and are easily oxidized, with a low upper temperature limit in oxidizing atmospheres. Boron base fibers are easily oxidized, similar to carbon fibers, yet have excellent heat-shock resistance and are noncombustible. Glass fibers, good insulators and noncombustible, can lose strength above about 315° C. Silicon carbide fibers can be resistant to oxidation at high temperatures, electrically conductive, noncombustible, and have excellent thermal conductivity. Metal fibers possess extremely high tensile strength, with other properties ranging between noncombustibility to oxidizing at low temperatures. The above mentioned fibers and others will hereafter be referred to as fibers. 
     Critical factors affecting the composites&#39; mechanical properties include fiber dispersion and orientation. For instance, composites containing unidirectionally oriented fibers possess high tensile strength in the direction of the fibers, and low tensile strength perpendicular to the fiber orientation; while randomly oriented fiber composites display a fairly uniform tensile strength in all directions. 
     One fabrication method for producing fiber reinforced composites having complex shapes and desired fiber orientation involves hot press molding of glass infiltrating woven and/or non-woven fiber preforms as described in U.S. Pat. No. 4,412,854 (incorporated herein by reference). Related techniques that are suitable for complex shapes, used with matrix transfer molding are described in U.S. Pat. Nos. 4,786,304 and 4,428,763 (incorporated herein by reference). Transfer molding, a process similar to injection molding, consists of softening thermoplastic resin in a chamber with heat and pressure and forcing it by high pressure through an orifice into a closed mold. 
     An injection molding technique, not requiring fiber pre-arrangement yet obtaining fiber dispersion, consists of injecting a discontinuous fiber/molding compound mixture into a die as disclosed in U.S. Pat. Nos. 4,464,192 and 4,780,432 (incorporated herein by reference). Injection molding, described in the above mentioned patents, consists of feeding a molding compound consisting of into a heating chamber and heating it to a viscous liquid, and then, via a plunger, forcing the material into a mold and keeping it under pressure until cool. 
     Injection molding of fiber reinforced molding compounds, without pre-arranged fibers, fail to fully solve the problem of obtaining a controllable fiber orientation which will produce the optimum mechanical strength. For example, in cylindrical orifice injection molding, as described in U.S. Pat. No. 4,780,432, fibers lie on paraboloidal shaped planes susceptible to crack propagation (FIG. 1B) between such planes. 
     The object of this invention is to introduce an oscillatory flow of the molding compound into the mold cavity, to produce a shaped composite with desired fiber dispersion and orientation obtaining superior, quasi isotropic, mechanical strength. 
     DISCLOSURE OF INVENTION 
     The present invention is directed to a method of forming fiber reinforced articles through injection molding. A mixture of molding compound and fibers are heated and pressurized to force the viscous mixture through an elongated slot-like injection port into a die. The injection port, a crucial aspect of the invention, is located essentially parallel to the major axial dimension of the article, is approximately the length of the article, is a fraction of the width of the article, and has a depth sufficient to orient the fibers with the flow. The injection port geometry and orientation relative to the mold cavity cause the fiber planes to form a whorled, accordion-like pattern within the article. The process results in the fiber planes becoming intertwined, creating superior tensile strength throughout the article. 
     The foregoing and other features and advantages of the present invention will become more apparent from the following description and accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     FIG.. 1A shows the fiber plane orientation obtained by axial cylindrical port injection molding. 
     FIG.. 1B shows the fiber plane orientation obtained by edge slot port injection molding. 
     FIG. 2A shows one embodiment of a die used with the present invention. 
     FIG. 2B shows a molded article formed using the present invention and the fiber plane orientation created. 
     FIG. 3 is a cross sectional view of an injection mold assembly useful with the present invention. 
     FIG. 4 is a schematic of the invention process. 
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION 
     A basic embodiment of the invention is shown in FIG. 2A where article (120) is the desired product produced using and injection port (130) of specific geometry and location; this being a crucial controlling factor of fiber plane orientation. The injection port&#39;s elongated slot-like geometry includes: a length (134) as close to the full length of the major axial dimension (124) as is practical to arrange, a thickness (138), usually, between about 30 and about 70 percent of the article thickness (122), a depth (136) sufficient to initially orient the fibers with the flow, and location essentially perpendicular to the major axial dimension (124) of the finished article. 
     Any high temperature thermoplastic resin, glass ceramic, or glass matrix/fiber system may be used as the molding compound in this process. On the basis of flexure strength, and oxidation and wear resistance of hot pressed chopped fiber composites, a glass matrix/carbon fiber was chosen for the specific application of a gas turbine engine inner shroud. The molding compound formulation range lies between 18 and 36 v/o carbon fiber to glass matrix, and especially between 25 and 30 v/o carbon fiber to glass matrix for the particular 1/2 inch carbon fiber and glass matrix used, and the optimum fiber length for the chosen article (FIG. 2A) is 1/2 inch. For finely detailed articles, the fiber length can be reduced to obtain the desirable fiber orientation throughout the article and good detailed surface replication. 
     The optimum fabrication temperature ranged from 1200° C. to 1275° C. for the particular carbon fiber/glass matrix system used. The viscosity, another significant factor and a function of the temperature, is approximately 10 6  -10 7  poise for HMU-3K fiber/7070 glass in this temperature range. Note, however, this is only the desired viscosity for the carbon fiber/glass matrix system used, different viscosity ranges may apply for the other viable thermoplastic resin, ceramic, or glass systems such as those described in U.S. Pat. Nos. 4,314,852, 4,324,843, and 3,926,904. 
     When the parameters mentioned above are satisfied (viscosity, temperature, and fiber length), a unique, whorled, accordion like fiber plane orientation results (FIG. 2B; obtained from (2B) in FIG. 2A). The viscosity, flow rate, and geometric relation between the injection port and mold cavity are presumed to create an oscillating flow pattern entering the die cavity (FIG. 4), which induces a folding of the fiber planes, causing them to become interlocked. Consequently, the article resists crack propagation on most planes. 
     The invention will be clarified by reference to the following illustrative example. 
     EXAMPLE The following procedure can be used to prepare a fiber reinforced glass article. 
     1. A preconsolidated molding compound of 25 to 30 v/o 1/2 inch Hercules Inc. HMU-3K carbon fiber/code 7070 low sodium borosilicate glass/colloidal silica (Ludox ) binder is placed in the reservoir (50) (FIG. 3), before inserting the plunger (40) into the injection mold assembly. 
     2. The mold assembly is placed below the ram (60) in a hot press furnace chamber; the two part mold assembly having a which has a height of 2.54 cm, a length of 7.62 cm, and a thickness of 1.11 cm, and has an injection port which has a length of 6.51 cm, a width of 0.57 cm, and a depth of 3.05 cm. 
     3. The mold assembly is heated to furnace temperature set point of 1275° C. 
     4. The ram (60) and plunger (40) are used to apply 1000 psi hydrostatic pressure when the thermocouple indicates 1100° C. 
     The molding compound volume flow rate, linear flow rate through the slot, and the viscosity obtained were calculated to be approximately 0.615 cc/sec, 0.163 cm/sec, and 4×10 6  poise respectively. FIGS. 1A and 1B show the results of this experiment as opposed to the prior art (test samples obtained as shown by (1) in FIG. 2A); the flexure strengths of a cylindrical port injection molded composite (FIG.. 1A) versus a slot port injection molded composite (FIG. 1B) (present invention). The flexure strengths of the axial cylindrical port injection molded composite were 6.9 KSI, 12.5 KSI, and 21.0 KSI. The flexure strengths of the edge slot port injection molded composite were 26.9 KSI, 28.7 KSI, and 29.9 KSI. It can clearly be seen from the fiber plane orientation within the samples and the test results that (FIG. 1A) possesses a relatively low flexure strength throughout the structure, while (FIG.. 1B) possess uniformly high flexure strengths with the desired fiber dispersion and fiber plane orientation. 
     Although this invention has been shown and described with respect to detailed embodiments thereof, it will be understood by those skilled in the art that various changes in form and detail thereof may be made without departing from the spirit and scope of the claimed invention.