Pultrusion process for preparing composites having low percentage of fibers and articles made from same

摘要

An improved pultrusion process for preparing composite materials having about 10 percent to about 45 percent by volume of reinforcing fibers so as to produce a composite material having enhanced flexibility as compared with composite materials having a higher percent of reinforcing fibers by volume. Articles of manufacture made from composite material produced by the improved pultrusion process, specifically spinal implants, are also provided.

主权项

1. A pultrusion process for-preparing a low percent of continuous reinforcing fibers composite material comprising the steps of:
continuously pulling reinforcing fibers through an impregnation chamber comprising a mixture containing precursors and initiators that polymerize when heated above a reaction temperature to produce impregnated continuous reinforcing fibers, wherein the temperature of the impregnation chamber is below the polymerization temperature of the precursors and initiators in the impregnation chamber; wrapping the continuous reinforcing fibers with strands of curable matrix material having a lower melting point than a melting point of the continuous reinforcing fibers, the continuous reinforcing fibers being selected from the group consisting of metallic wire, carbon fibers, polyolefin fibers, polyester fibers, and aromatic polyamide fibers; directing the wrapped continuous reinforcing fibers through a heated curing die to melt the matrix material about the wrapped continuous reinforcing fibers and cure the matrix material so as to produce a solid fiber reinforced composite; and withdrawing the solid fiber reinforced composite from the curing die, wherein the percentage of continuous fibers in the solid fiber reinforced composite is between about 10 percent by volume and about 45 percent by volume.