Thomas R Carter

US Patent:

6565793, May 20, 2003

Filed:

Sep 11, 1998

Appl. No.:

09/152170

Inventors:

William B. Goldsworthy - Palos Veredes Estates CA
George J. Korzeniowski - Sherman Oaks CA
Thomas G. Carter - Kent OH

Assignee:

Essef Corporation - Cincinnati OH

International Classification:

B29C 7044

US Classification:

264516, 264257, 264258, 264314, 156156, 156172, 220589, 220590

Abstract:

A process of fabricating a composite vessel includes the steps of: A) fabricating a thermoplastic liner for the vessel; B) overlaying a layer comprising fiber and a thermoplastic material (preferably by winding commingled filaments, rovings or yarns) onto the thermoplastic liner to obtain a composite intermediate structure (the fiber and thermoplastic material can be heated if desired during the overlaying, e. g. winding, step); C) heating the composite intermediate structure in a mold while applying at least one force thereto tending to urge the composite intermediate structure against and into the shape of the interior walls of the mold; D) continuing step C) until the thermoplastic liner and the overlaid layer consolidate to form a composite vessel; E) cooling the mold and composite vessel until the composite vessel is solidified; and F) removing the formed composite vessel from the mold. The at least one force applied during step C) may be obtained by introducing gas pressure into the interior of the composite intermediate structure. Suitable materials for the thermoplastic material include: polyethylene, polypropylene, polybutylene terephthalate and polyethylene terephthalate.