US 11,919,254 B2
Method of manufacturing a composite material
Erik John Kiilunen, Hubbell, MI (US); Kenneth Brian Keranen, Hancock, MI (US); and Matthew Paul Kero, Calumet, MI (US)
Assigned to Neuvokas Corporation, Ahmeek, MI (US)
Filed by Neuvokas Corporation, Ahmeek, MI (US)
Filed on Nov. 12, 2020, as Appl. No. 17/096,373.
Claims priority of provisional application 62/934,158, filed on Nov. 12, 2019.
Prior Publication US 2021/0138740 A1, May 13, 2021
Int. Cl. B29C 70/52 (2006.01); B29C 48/00 (2019.01); B29C 70/02 (2006.01); B29C 70/54 (2006.01); B29K 105/08 (2006.01)
CPC B29C 70/021 (2013.01) [B29C 48/022 (2019.02); B29C 70/521 (2013.01); B29C 70/523 (2013.01); B29C 70/543 (2013.01); B29C 70/548 (2013.01); B29K 2105/08 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A method of manufacturing a structural member, the method comprising:
applying a binder having a viscosity less than 25 centipoise (cP) at 30° C. to at least one of a plurality of fibers, wherein when the binder is applied, the fibers are spaced apart and extend across a first area;
providing a die having a first portion with a first diameter positioned to receive the fibers and a second portion with a second diameter positioned downstream of the first portion, wherein the first diameter is greater than the second diameter and wherein the die is tapered between the first portion and the second portion;
after applying the binder, guiding the plurality of fibers along the die at a speed of at least 25 feet per minute;
decreasing a distance between the plurality of fibers with the die, wherein after decreasing the distance between the plurality of fibers, the fibers extend across a second area that is smaller than the first area; and
after decreasing the distance, shaping the plurality of fibers with a shaping station,
wherein the binder includes Tricyclopentadiene (TCPD).