Patent US5294391A successfully refreshed from Google Patents.
US5294391A
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Method of making a fiber reinforced composite structure including randomizing the reinforcing fibers
Assignee: DePuy Spine LLC
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Filing: 1993-01-26
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Granted: 1994-03-15
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Expires: 2013-01-26
Abstract
Abstract A method of forming a three-dimensional fiber reinforced composite structure includes comprises the steps of providing yarn made of a plurality of continuous reinforcing fibers and fibers which when melted form a matrix material, randomizing the yarn, forming the randomized yarn into a preform, and consolidating the preform in one direction. Each of the plurality of reinforcing fibers extends continuously and randomly throughout the matrix because of the randomizing. The fiber reinforced composite structure formed by the present method is particularly suitable for manufacturing a vertebral prosthetic spinal implant device.
Inventors
- 👤 Carl R. McMillin
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 17:48
CPC Classifications
A; A61; A61F; A61F2/00; A61F2/02; A61F2/30; A61F2/3094; A61F2/30965; A61F2/44; A61F2/4455; A61F2/447; B; B29; B29C; B29C70/00; B29C70/04; B29C70/28; B29C70/30; B29C70/38; A61F2/442; A61F2/28; A61F2002/2835; A61F2002/30001; A61F2002/30108; A61F2002/30199; A61F2002/30224; A61F2002/30261; A61F2002/30316; A61F2002/30535; A61F2002/30593; A61F2002/30594; A61F2/30767; A61F2/30771; A61F2002/30772; A61F2002/30774; A61F2002/30777; A61F2002/30904; A61F2230/00; A61F2230/0063; A61F2230/0069; A61F2230/0082; B29L; B29L2031/00; B29L2031/753; B29L2031/7532; Y; Y10; Y10T; Y10T428/00; Y10T428/29; Y10T428/2913; Y10T428/2922; Y10T428/2924; Y10T428/2925
Claims Analysis
Total Claims: 19
Claim 1
Independent Claim
202 words
A method of forming a fiber reinforced composite structure comprising the steps of: providing one-piece of yarn having a length and two ends and made of a plurality of continuous reinforcing fibers and other material which other material is to become a matrix, each of the plurality of reinforcing fibers having a length equal to the length of the one piece of yarn; randomizing the reinforcing fibers and the other material to extend randomly in substantially equal proportion in three dimensions throughout a mass of the yarn to intertwine and interlock the reinforcing fibers and the other material; forming the randomized yarn into a preform; consolidating the preform in a Z direction which is perpendicular to X and Y directions and causing a majority proportion of the reinforcing fibers to lie randomly in substantially two dimensions defined by a plane extending in X and Y directions and a minority proportion of the reinforcing fibers to weave through the plane in the Z direction; and melting the other material to form a matrix containing the continuous reinforcing fibers extending randomly in X, Y and Z directions throughout the matrix and have a length equal to the length of the one piece of yarn.
Claim 2
Independent Claim
202 words
A method of forming a fiber reinforced composite structure comprising the steps of: providing one-piece of yarn having a length and two ends and made of a plurality of continuous reinforcing fibers and other material which other material is to become a matrix, each of the plurality of reinforcing fibers having a length equal to the length of the one piece of yarn; randomizing the reinforcing fibers and the other material to extend randomly in substantially equal proportion in three dimensions throughout a mass of the yarn to intertwine and interlock the reinforcing fibers and the other material; forming the randomized yarn into a preform; consolidating the preform in a Z direction which is perpendicular to X and Y directions and causing a majority proportion of the reinforcing fibers to lie randomly in substantially two dimensions defined by a plane extending in X and Y directions and a minority proportion of the reinforcing fibers to weave through the plane in the Z direction; and melting the other material to form a matrix containing the continuous reinforcing fibers extending randomly in X, Y and Z directions throughout the matrix and have a length equal to the length of the one piece of yarn.
Claim 3
Dependent Claim
48 words
A method as set forth in claim 1 wherein the continuous reinforcing fibers include at least one of carbon fiber, glass fiber, silicon carbide fiber, aluminum oxide fiber and combinations thereof and the other material includes at least one of a polymer, a metal and a combination thereof.
Claim 4
Dependent Claim
42 words
A method as set forth in claim 2 wherein the continuous reinforcing fibers comprise carbon fibers and the other material comprises polymer fibers, each of the carbon fibers and the polymer fibers having a length equal to the length of the yarn.
Claim 5
Dependent Claim
17 words
A method as set forth in claim 2 wherein the other material comprises a metal including titanium.
Claim 6
Dependent Claim
28 words
A method as set forth in claim 1 wherein the continuous reinforcing fibers are carbon fibers and the other material comprises polymer particles bonded to the carbon fibers.
Claim 7
Dependent Claim
29 words
A method as set forth in claim 1 wherein the continuous reinforcing fibers are carbon fibers and the other material is a coating of polymer on the carbon fibers.
Claim 8
Dependent Claim
29 words
A method as set forth in claim 1 wherein said step on randomizing the yarn includes hooking the yarn with a hook and moving the hook through the yarn.
Claim 9
Dependent Claim
23 words
A method as set forth in claim 7 further including a step of cleaning the yarn during said step of randomizing the yarn.
Claim 10
Dependent Claim
21 words
A method as set forth in claim 1 further including a step of spreading the yarn before said step of randomizing.
Claim 11
Dependent Claim
25 words
A method as set forth in claim 1 wherein said step of consolidating includes compression molding the preform at a temperature of about 800° F.
Claim 12
Dependent Claim
22 words
A method as set forth in claim 1 further includng cooling the matrix and, subsequent to cooling the matrix, shaping the structure.
Claim 13
Dependent Claim
25 words
A method as set forth in claim 11 wherein said step of shaping the structure includes cutting the structure to form a prosthetic implant device.
Claim 14
Dependent Claim
29 words
A method as set forth in claim 12 wherein said step of cutting the structure includes cutting a plurality of serrated teeth and an aperture extending into the structure.
Claim 15
Independent Claim
83 words
A method of forming a fiber reinforced composite structure comprising the steps of: providing a yarn made of a plurality of continuous reinforcing fibers and other materials which is to become a matrix; randomizing the yarn by hooking the yarn with a hook and moving the hook through the yarn; forming the randomized yarn into a preform; consolidating the preform in one direction; and melting the other material to form a matrix containing the continuous reinforcing fibers which are randomized throughout the matrix.
Claim 16
Independent Claim
83 words
A method of forming a fiber reinforced composite structure comprising the steps of: providing a yarn made of a plurality of continuous reinforcing fibers and other materials which is to become a matrix; randomizing the yarn by hooking the yarn with a hook and moving the hook through the yarn; forming the randomized yarn into a preform; consolidating the preform in one direction; and melting the other material to form a matrix containing the continuous reinforcing fibers which are randomized throughout the matrix.
Claim 17
Dependent Claim
23 words
A method as set forth in claim 14 further including a step of cleaning the yarn during said step of randomizing the yarn.
Claim 18
Dependent Claim
39 words
A method as set forth in claim 15 wherein said step of cleaning the yarn includes soaking the yarn in a bath of acetone; removing the randomized yarn; and soaking the randomized yarn in a bath of distilled water.
Claim 19
Dependent Claim
43 words
A method as set forth in claim 14 wherein a majority of the reinforcing fibers lie randomly and substantially parallel with a plane extending in X and Y directions and portions of the reinforcing fibers weave through the plane in a Z direction.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1997-03-14 | 1997-09-13 | 1998-03-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2001-03-14 | 2001-09-13 | 2002-03-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2005-03-14 | 2005-09-13 | 2006-03-15 | $7700.00 | Window Closed / Lapsed |